Operators Manual DRF400-450

Reachstackers 40-45 tonnes
Publ. no IDRF03.03GB
Operator's Manual in original OPERATOR´S MANUAL
DRF 400-450
1 Foreword......................................................................................................... 3
1.1 About the operator’s manual ...................................................................... 3
1.2 About the documentation kit ....................................................................... 6
1.3 Inspection and maintenance ...................................................................... 6
2 Safety .............................................................................................................. 7
2.1 Safety and emergency equipment .............................................................. 8
2.2 CE-marking .............................................................................................. 10
2.3 ANSI/ITSDF marking ................................................................................ 10
2.4 Keep in mind ............................................................................................ 11
2.5 Fire ........................................................................................................... 20
3 Overview ....................................................................................................... 23
3.1 Description DRF 400-450 ......................................................................... 23
3.2 Plates ....................................................................................................... 29
4 Instruments and controls ............................................................................ 37
4.1 Warning and indicator lights ..................................................................... 42
4.2 Instruments ............................................................................................... 46
4.3 Ignition ...................................................................................................... 47
4.4 Switches ................................................................................................... 48
4.5 Gear selector and
multi-function lever ..................................................................... 57
4.6 Control lever ............................................................................................. 59
4.7 Pedals ...................................................................................................... 62
4.8 Steering wheel .......................................................................................... 63
4.9 Driver’s seat ............................................................................................. 66
4.10 Heating / Air conditioning ......................................................................... 69
4.11 Control system ......................................................................................... 72
5 Handling........................................................................................................ 83
5.1 Running-in ................................................................................................ 86
5.2 Daily inspection ........................................................................................ 87
5.3 Error codes ............................................................................................... 88
5.4 Operating ................................................................................................ 139
5.5 Load handling ......................................................................................... 152
6 Inspection and maintenance..................................................................... 169
6.1 Daily inspection ...................................................................................... 170
6.2 Maintenance ........................................................................................... 173
6.3 Service ................................................................................................... 200
7 Transporting the machine ......................................................................... 203
7.1 Towing .................................................................................................... 204
7.2 Lifting and transporting the machine ...................................................... 206
7.3 Service position ...................................................................................... 218
7.4 Long-term storage .................................................................................. 218
8 Environment and standards...................................................................... 219
9 Specifications............................................................................................. 223
10 Terminology................................................................................................ 233
11 Index............................................................................................................ 237
1 Foreword 3
1 Foreword
1 Foreword
mm mm mm mm mm mm
1.1 About the operator’s manual

General
page
–
Thank you for choosing Cargotec as your machine supplier. We hope

that we’ll meet your expectations.
This Operator’s manual contains information that you must keep in
mind for safe handling and optimal use of your new machine.
Operator’s manual, purpose

–
This Operator’s manual applies to machine DRF 400-450.

The operator’s manual describes how the machine should be operat-
ed and maintained in a correct manner.
Storage
–
The operator’s manual should always be kept in the machine.
About machine version

–
The information in this operator’s manual corresponds to the ma-

chine’s design and appearance at the time of delivery from Cargotec.
Due to customer adaptations, there may be variations and/or
deviations.
Cargotec reserves the right to modify specifications and equipment
without prior notice. All information and data in the manual are valid at
the time of publication.
Copyright
–
Cargotec Sweden AB
Duplication of the content in this manual, in whole or in part, is strictly
prohibited without written permission from Cargotec Sweden AB.
All duplication by any means, such as copying, printing, etc., is
prohibited.
Manufacturer
–
This machine is manufactured by Cargotec Sweden AB,

SE-340 10 Lidhult, Sweden.
Operator’s manual DRF 400-450 IDRF03.03GB

4 1 Foreword – 1.1.1 Reading instructions
1.1.1 Reading instructions

Warning information
page
–
This operator’s manual contains warnings that involve your safety.

The warnings provide information on potential dangers that, if not
heeded, could lead to personal injury or product damage.
DANGER
Situation that could lead to severe personal injury or
death if regulation is not followed.
WARNING
Situation that could lead to personal injury if regula-
tion is not followed.
CAUTION
Situation that could lead to product damage if regula-
tion is not followed.
Important information
–
Important information is denoted with NOTE and is intended to facili-

tate the work process, handling or to increase understanding of the
information.
NOTE
Important information not related to safety.
IDRF03.03GB Operator’s manual DRF 400-450

1 Foreword – 1.1.1 Reading instructions 5
Read operator’s manual

–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Operator’s manual.
000262
Read the operator’s manual
Read the Maintenance manual
–
The symbol to the left is used in certain cases on the machine and re-
fers to important information in the Maintenance manual.
001128
Read the Maintenance manual
Optional equipment
–
There is a wide range of optional equipment for the machine. Each de-
000264
scription of optional equipment in the operator’s manual is marked with
a symbol and contains an explanatory text. The symbol is highly visible
Indicates optional equipment and is placed next to the text and figure item in question.
See the machine card for complete specifications of the machine’s
product alternatives and optional equipment.

6 1 Foreword – 1.2 About the documentation kit
1.2 About the documentation kit

The documentation kit
page
–
The following documentation is supplied with the machine:

• Instruktionsbok DRF 400-450 (in cab with machine)
• Maintenance manual DRF 400-450
• Spare parts catalogue with machine card
There is supplementary documentation that can be ordered for the
machine:
• Workshop manual DRF 400-450.
• Supplier documentation for engine, transmission, and drive axle.
Ordering documentation
–
The documentation is ordered from the dealer for Cargotec.

Always indicate publication number when ordering.
1.3 Inspection and maintenance

General
page
–
For satisfactory function of the machine to the lowest cost, mainte-

nance must be performed correctly. Intervals for inspection and main-
tenance refer to normal environment and operating conditions.
Maintenance work described in this operator’s manual can be per-
formed by the operator, see chapter 6 Inspection and maintenance.
This section describes the running checks and actions that the opera-
tor should perform in connection with starting work shifts.
Maintenance
–
For other maintenance not included in this operator’s manual (service

and repairs), contact an authorised workshop.

2 Safety 7
2 Safety
2 Safety
mm mm mm mm mm mm
General
page
–
Safety rules are intended to reduce the risk of personal injuries as well
as damage to the load or other property.
Important to read the operator’s

–
manual
Incorrect handling can lead to personal injuries and damage to product
and/or property. Therefore, read the Operator’s Manual very thorough-
ly before starting to use the machine. The Operator’s Manual contains
important information about your Kalmar machine, handling the ma-
chine, safety during operation, and daily maintenance of the machine.
000262
You will also find a lot of valuable information that will make your work
easier.
The operator’s manual should always be kept in the machine. If it is
lost, replace it immediately with a new operator’s manual.
NOTE
Never use a machine that does not have an operator’s manual.
Ask your foreman or supervisor if there is anything in the text you do
not understand or if you feel information is missing in any area.
Intended use
–
• The machine may only be used for the purpose for which it is de-
signed and adapted, that is, to lift and transport goods (the weight
of which is not to exceed the machine’s max. allowed load capac-
ity). If it is used in another way or in potentially dangerous environ-
ments (e.g. explosive environment, area with dust containing
asbestos), special safety regulations must be followed and the
machine must be equipped for such operation.
• The machine may not be modified or rebuilt without permission
from Cargotec. For modifications approved by Cargotec, affected
plates on the machine and documentation shall be adapted to ap-
ply to the modification.
Any modification or rebuild without Cargotec’s permissions can-
cels Cargotec’s product responsibility. Modifications and rebuilds
may only be done if the knowledge exists to verify and test modi-
fications and rebuilds. Modifications and rebuilds shall be docu-
mented (dates and actions) and responsible organisation shall be
stated with name and address. Plates and decals shall be updat-
ed according to the machine’s new version.

8 2 Safety – 2.1 Safety and emergency equipment
• The machine may not be operated on public roads unless it has

been adapted according to national road safety regulations.
• It is always the machine owner’s responsibility to ensure that the
machine has approved fire-fighting equipment according to gov-
erning regulations.
• The machine is designed for use in outdoor temperatures -40 °C
to 40 °C, relative humidity 10 to 90%, and max. wind speeds
12.2 m/s. In the event of deviations from this, contact Cargotec.
Operator requirements
–
• The machine may only be operated by specially trained operators

who have the work supervisor’s permission to operate the
machine.
• Laws and regulations regarding driver’s licenses, operator ID, etc.
must always be followed.
• The operator must be aware of and follow all local safety rules.
Prohibited operation
–
Machine operation is prohibited:

• If safety and warning equipment such as rear view mirrors, head-
lights, etc., do not function correctly.
• In case of defective brakes, steering or lifting equipment.
• If the machine has been repaired, modified or adjusted without the
supervisor’s/work management’s permission.
• If the machine is equipped with tyres not approved by Cargotec.
• Overload system (OP) for load handling is not working.
2.1 Safety and emergency

equipment
General
page
–
A good working environment has safety and warning equipment to

make the operator’s work easier and safer.
The machine may be equipped with the following safety equipment:
1. Back-up alarm
2. Revolving beacon
3. Horn
4. Electrically powered loud air horn

2 Safety – 2.1 Safety and emergency equipment 9
5. Fire extinguisher
A fire extinguisher may also be located externally.
If the machine is provided with a fire extinguisher, it should be of
the type ABE according to EN3 pt. 1, 2, 4, and 5. With such a fire
extinguisher, it is possible to put out fires in both solid organic ma-
terials and fluids. Adapted fire extinguishing equipment can be or-
dered from Cargotec.
6. Seat belt
For hydraulic vertically adjustable cab, there’s always a seatbelt
and safety chains by the doors.
7. Buzzer in cab to indicate alarm, overload or forgotten action, for
example, leaving cab without applying the parking brake.
8. Camera with monitor

Used to give improved rearward visibility during operation of the
machine. Monitor is located inside the cab on the left side.
9. Back-up light
10. External rear view mirrors
Used to give improved visibility when operating and load handling.
One rear view mirror on each side.
11. Control breaker for hydraulics
Cuts off all power supply and control signals to hydraulics.
12. Emergency exit, right door and rear window ( )

(Not located in illustration)
2
7
1, 8, 9 11
4
003637
5 6 3 10

10 2 Safety – 2.2 CE-marking
2.2 CE-marking
CE-marking
page
–
(Declaration of Conformity, only applies to machines marketed

within EU/EEA).
This machine is CE-marked. This means that upon delivery it fulfils the
applicable "Essential Health and Safety Requirements" specified in
the EU Machine Directive, 2006/42/EC, as well as other EU directives
relevant to this machine type.
As proof that the requirements have been fulfilled, Cargotec issues
and delivers an EC Declaration of Conformity for each individual ma-
013979
chine. This Declaration of Conformity also covers attachments and op-
tions manufactured by Cargotec. The documentation is valuable and
should be kept in a safe location and saved at least 10 years. The doc-
Machine plates for CE-marking, machine and umentation should always accompany the machine when it is sold.
attachment See example of EC Declaration after 11 Index.
Anyone making modifications that affect the safety of the machine as-
sumes responsibility for them. If the machine is used for purposes or
with attachments other than that specified in these instructions, safety
must be ensured in each individual case. The machine owner is re-
sponsible for ensuring that the machine is used as specified in the op-
erator’s manual. In some cases, the type of use may require a new
CE-marking and the issue of a new EU Declaration of Conformity.
For additional information, see standards under chapter 8 Environ-
ment and standards.
2.3 ANSI/ITSDF marking

ANSI/ITSDF marking
page
–
Only applies to machines for the North American market.

This machine is ANSI/ITSDF marked. This means that upon delivery
it fulfils the basic safety requirements of ANSI/ITSDF B56.1.
Anyone making modifications that affect the safety of the machine also
assumes responsibility for them.
If the machine is used for purposes or with attachments other than
those specified in these instructions, safety must be ensured in each
individual case. The machine owner is responsible for ensuring that
the machine is used as specified in the operator’s manual.
014253
For additional information, see standards under chapter 8 Environ-

Machine plates for ANSI / ITSDF-marking, machine ment and standards.
and attachment

2 Safety – 2.4 Keep in mind 11
2.4 Keep in mind

Interrupted operation and/or parking
page
–
WARNING
Always turn off the electric power when the machine
is left, e.g. when parking or at the end of the shift.
Risk of fire!
Turn off the electric power with the battery

disconnector.
NOTE
Never leave the operator’s station without first applying the park-
ing brake (ON position).
NOTE
Always remove the start key if the machine is to be left
unattended.

12 2 Safety – 2.4 Keep in mind
During work shifts

–
DANGER
The attachment is a tool that handles heavy loads.
Extreme hazard to personal health and risk of proper-

ty damage!
Never walk under a suspended load. Never walk un-

der a raised attachment, whether it is loaded or not.
DANGER
Forks or other attachments are work tools that handle
large loads.

ty damage!
Make sure that no persons stand or walk under a

raised work attachment, regardless of whether it is
loaded or not.
DANGER
External equipment may only be used if it is approved
by Cargotec.

ty damage!
Only use equipment that is approved by Cargotec.
DANGER
The parking brake should not be applied when the
machine is in motion.
Very sudden braking. Risk of machine tipping over,

load tipping over or being dropped, or damage to
property or extreme danger!
Stop the machine before applying the parking brake.

DANGER
The machine’s work area is large and visibility from
the operator’s cab is restricted.

ty damage!
Keep in mind:
• Always check that no persons are in the way of the

machine or its accessories. Also check that the
area upwards is free. Stop the machine if there are
unauthorised persons or vehicles within the work
area.
• The operator must always face in the travel direc-

tion and should operate with special care where
persons or vehicles may appear.
• The operator must adapt the speed to the load and

ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate

with special care near electric power lines, via-
ducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment

does not collide with posts, power lines, etc.
• Use available visibility-enhancing equipment

such as rear view mirrors and camera .

WARNING
Transporting loads is associated with major risks.
Risk of roll-over and tipping! Risk of load damage to

property!
Respect the lifting capacity of the machine and exer-

cise the greatest caution during load handling:
• The machine must only be operated on even sur-

faces, intended for the machine’s total weight and
ground pressure.
• All loads should be carried in the transport posi-

tion. Always operate carefully; keep in mind the
width and height so that the boom or attachment
• Do not transport the load in high position since

this may cause the machine to roll or tip over.
• Always operate with the load facing uphill on an

uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported

load obscures visibility to the front.
• No personnel may encroach or stand under a

raised load.
• The operator must avoid forceful acceleration and

sudden braking.
• The operator must always adjust the speed when

turning to prevent skidding and risk of roll-over or
tipping over.
In the event that the machine rolls over or tips,

hold onto the steering wheel and always stay in
the cab. Do NOT try to jump out of the cab until the
machine has stopped moving.
Local regulations may apply when handling spe-

cial loads. Learn about them and follow them.

WARNING
The machine’s load capacity is limited!
Risk of roll-over and tipping over!
Do not exceed the machine’s load capacity. See the

marking plate and load diagram. The machine’s sta-
bility limit may be exceeded if the overload system is
not working.
WARNING
The strength of the roof window may be significantly
reduced in the event of exposure to substances con-
taining aromatic hydrocarbons, ketones, esters or
chlorinated hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Rinse thoroughly with
plenty of lukewarm water. Replace a damaged roof
window immediately if it is cracked or scratched!
WARNING
Lifting loads in very windy conditions is associated
with great difficulties.
Avoid lifting loads at wind speeds higher than

12.2 m/s.
WARNING
The machine emits exhausts during operation.
Health hazards and fatal danger in poorly ventilated

facilities!
If possible, avoid operating the machine indoors in

poorly ventilated facilities. Use exhaust venting
equipment!

WARNING
The work position on the machine is at a high level.
Always use the steps and handles when you climb up
or down from the machine. Always face the machine.
Do not jump!
Risk of falling and bodily injury!
WARNING
Cab doors must always be closed when operating.
Risk of personal injury and crushing in case of roll-

over and tipping!
Always close the operator door(s) during the work

shift.
WARNING
Passengers are only allowed in the cab if there is a
specific passenger seat. It is prohibited to carry pas-
sengers on the machine outside the cab or on the
load.
Risk of personal injury!
A passenger in the cab must use a permanently

mounted extra passenger seat and seatbelt.

WARNING
The cab has the sliding cab feature, manual or hy-
draulic ( ). The cab must ALWAYS be in its rear-
most position during operation.
Warning - risk of crushing!
For manual sliding cab, always make sure that the cab
is locked in its rearmost position before operating,
and that the locks on both sides are secured with the
lock pins.
For hydraulic longitudinal displacement, the cab may

be positioned as desired (locking is automatic) during
stationary load handling.
WARNING
The machine’s hydraulic system includes accumula-
tors with high pressure.
Always be very careful when working with the hydrau-

lic system, and avoid standing close to hydraulic
components or hoses. Before working on the hydrau-
lic system, the accumulators must be drained (see
Maintenance manual).
WARNING
Handle batteries and connectors with care when
charging and during starts with booster batteries. Do
not mix up the battery terminals! Follow instructions
for starting with booster battery!
Risk of short-circuiting! Warning - generation of oxy-

hydrogen gas! Sparks and fire hazard! Oxy-hydrogen
gas is very explosive!
Batteries should always be provided with protective

caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that may
ignite the hydrogen gas.

WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!
Avoid skin contact with oils and lubricants. Use pro-

tective gloves.
WARNING
Fire extinguishers contain dry chemicals.
Risk of breathing difficulties when using in an en-

closed space!
Use the fire extinguisher from the outside and into the
area that is to be extinguished. After use, ventilate the
area thoroughly.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking perform-

ance! Unwanted movement of parked machine!
Following emergency braking with the parking brake,

check the brake pads as soon as possible, change if
necessary! Braking action of the parking brake may
be lost as the brake pads may have been worn down.
If the parking brake has been released mechanically

then it must always be reset to restore the machine’s
parking brake function.

WARNING
Optional equipment such as two-way radio, RMI, tele-
phone, etc. may emit non-ionising radiation.
Risk of interference with active or non-active medical

products.
Use two-way radio, RMI, telephone, etc. when no per-

sons with active or non-active medical products are
nearby.
NOTE
When persons with active or non-active medical products are not
nearby, telephone and two-way radio may be used in the cab.
Equipment should not be used during operation or load handling
as this takes away from the operator’s concentration.
Cargotec will not assume any responsibility for installed optional
equipment, which is not installed by Cargotec or an installer ap-
proved by Cargotec.

20 2 Safety – 2.5 Fire
2.5 Fire
Action in the event of fire
page
–
DANGER
In the event of fire the operator’s safety must not be
compromised.
If given the opportunity, take the following action at

the slightest sign of fire:
• Stop the machine and turn the ignition key to stop

position.
• Leave the cab.
• Switch off the system voltage with the battery

disconnector.
• Alert the rescue services.
• Try to extinguish the fire.
• If this is not possible, leave the machine and the

risk area.
DANGER
Smoke can be extremely toxic.
Smoke anaesthetises, suffocates, and can kill people.

Even small quantities of smoke can cause damage to
the lungs and respiratory tract.
Avoid breathing in fumes, do not stand in the smoke.

Use respiratory protection for fire fighting and work
with burnt material.
page
–

2 Safety – 2.5 Fire 21
Fire prevention measures
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove combustible material residue from the en-

gine compartment as soon it is discovered, be espe-
cially careful on hot surfaces such as exhaust
systems, manifolds or turbos. If oil, fuel or coolant
leakage is detected, establish the cause and remedy
before starting the engine.
Make a habit of visually inspecting the engine and engine compart-

ment before starting the engine and after operation, when the engine
has stopped. This helps to quickly detect anything abnormal has hap-
pened or is about to happen. Look particularly closely for oil, fuel or
coolant leakage, loose bolts, worn or badly tightened transmission
belts, loose connections, damaged hoses and electrical cables. The
inspection only takes a few minutes and can prevent serious faults and
costly repairs.
CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
Do not use a high-pressure washer on the cab, radia-

tor, battery compartment, electric components, con-
trol units, connectors, cable joints, cylinder seals,
stub axles, axle seals and chains.

22 2 Safety – 2.5 Fire
Action after fire

page
–
When handling a machine damaged by fire, or exposed to excessive

heat, the following safety regulations must always be followed:
• Check that the fire is properly extinguished. Post-extinguish, if
necessary.
• Make sure that system voltage is switched off with the battery
disconnector.
• Make sure that the machine is in a secure location, service
position.
• Check for that there are no leaks which could cause damage to
the surrounding environment.
• Never touch the burned components with bare hands in order to
avoid coming into contact with molten polymer material.
• Use breathing apparatus, thick gloves and protective safety
goggles.
• Contact Cargotec.

3 Overview 23
3 Overview
3 Overview
mm mm mm mm mm mm
3.1 Description DRF 400-450

General
page
–
Machine DRF 400-450 is a reachstacker for handling containers and

trailer goods (with bottom lift attachment). It has a lift capacity of 40 to
45 tons and a lift height of 5 or 6 containers (9’ 6" container).
3.1.1 Identification of the machine

Type designation of reachstacker
page
–
Each machine from Cargotec has a type designation. Example: Type

designation DRF 450-65S5XS indicates the following:
• D – Diesel engine
• R – Reachstacker
• F – Generation
• 450 – Lift capacity, 1st row, decitonne
• 65 – Axle distance, decimetre
• S – Spreading, adjustable top lift
• 5 – Max. no. of containers when stacking
• X – Extra counterweight
• S – Support jacks
Machine card
–
It’s possible to modify and adapt Cargotec Industries’ machines in dif-

ferent ways with product alternatives and optional equipment. This
makes it possible to satisfy a very wide range of customers.
A machine card is delivered together with the spare parts catalogue.
The machine card contains a complete specification of the machine’s
product alternatives and optional equipment.
The machine card must be updated when the machine is modified and
Cargotec must be informed.

24 3 Overview – 3.1.2 Overview description
3.1.2 Overview description

General
page
–
This section provides a short presentation of the machine’s parts,

which are pointed out in the overview figure below.
7 6
003670
1 2 3 4 5
1. Steering axle
2. Engine
3. Transmission
4. Drive axle
5. Attachment
6. Boom
7. Cab

3 Overview – 3.1.2 Overview description 25
Engine
–
The machine has several engine options. The engines are straight
6-cylinder, turbocharged low-emission engines with intercooler. The
engine provides power for propulsion and working hydraulics.
The machine is equipped with one of the following engine alternatives:
• Volvo TAD1250VE
• Volvo TWD1240VE
• Cummins QSM11
Transmission
–
The transmission is fully automatic with a torque converter. The hy-

draulic pumps for the working hydraulics are mounted on the
transmission.
The machine is equipped with one of the following transmission
alternatives:
• Dana TE32 has 4 forward gears and 4 reverse gears.
• ZF 5WG261 has 5 forward gears and 3 reverse gears
Drive axle
–
The drive axle (front axle) is equipped with a differential and hub re-
ductions of the planetary gear type.
Brakes
–
The machine has one brake circuit and is equipped with hydraulically
operated brakes. The brake units consist of fully sealed oil-cooled disc
brakes with external cooling.
The parking brake is controlled electro-hydraulically and brakes with a
disc brake. The disc brake acts on the drive axle’s input shaft. The
parking brake is applied by spring force and is released with hydraulic
pressure. The parking brake is applied automatically if the ignition is
turned off.
Steering
–
The machine is steered with the rear axle. A double-acting hydraulic

cylinder acts on the wheel pair. Steering is linear, that is, the steering
angle is dependent on the number of steering wheel turns.
Load handling
–
The boom and attachment are used for load handling. The boom is op-
erated vertically (angle) and longitudinally (length).
Attachments are available in different versions. The attachment holds
the load. Securing of the load and operation of the attachment is con-
trolled electro-hydraulically.
One of the following alternatives is selected for the machine:
• Top lift attachment with side shift ±800 mm.
• Top lift attachment with hydraulic levelling (with side shift
±800 mm).
• Top lift attachment with overheight legs.

• Bottom lift attachment (handles containers and trailers).

• Tool carrier (handles different lifting tools).
Electrical system
–
The electrical system consists of electrical and electromagnetic com-

ponents such as battery, switches, cable harnesses, solenoid valves,
fuses and relays.
Control system
–
The machine has a computer-based control and monitoring system for

monitoring and controlling the machine’s functions as well as handling
all functions in the machine, such as power electronics, drivetrain and
hydraulic system. The control and monitoring system facilitates
maintenance.
Cab
–
The cab is available in one version. Instrumentation and equipment

(steering wheel, operator’s seat, fresh air system) can be customised
and model-adapted.
• Cab Spirit Delta
Spirit Delta is a closed cab constructed of a structural frame to
withstand falling loads in accordance with applicable standards. It
is equipped with a fresh air system with filtered inlet, recirculation
as well as heating and air conditioning ( ).
The roof window is made of high-strength material and withstands
heavy blows, e.g. from falling objects.
The cab can be moved fore-aft, either manually or hydraulically
( ), or vertically adjustable ( ).
Hydraulic system
–
The hydraulic system is divided in two parts, working hydraulics and

brake system.
The working hydraulics consist of hydraulics for steering, load han-
dling and cab functions. The working hydraulics are supplied from two
(machines with ZF 5WG261) or four (machines with Dana TE32) var-
iable axial piston pumps and a fixed gear-pump for cleaning and cool-
ing of the hydraulic oil. The hydraulic oil is cleaned with low-pressure
filter in the hydraulic tank and/or high-pressure filter ( ) after the hy-
draulic pumps.
The brake system is separated from the working hydraulics with its
own tank, fixed gear-pump, high-pressure filter, accumulators and
cooler.

3 Overview – 3.1.2 Overview description 27
Other equipment
–
17 23 1 26, 27 5, 22 35 15, 16 26, 27 11 12 14 13
006439
6, 17 18 3 4 2 24, 25 28, 29 28, 29 23, 24 2 20 31 7 35 36
1 Interior rear view mirror

2 External rear view mirrors
3 Horn
Located under cab.
4 Noise insulation under engine compartment
5 Electrically powered loud air horn

Located at leading edge cab.
6 Back-up alarm
7 Passenger seat
8 Tinted windows (Not positioned in figure)
9 Openable window left door (Not positioned in figure)
10 Openable window right door (Not positioned in figure)
11 Sun visor, front windscreen

Adjustable up-down with string. Select position with string lock.
12 Sun visor, roof window

Can be pulled out to leading edge. Secured in position with
two hooks.
13 Sun visor, rear window

Adjustable up-down with string. Select position with string lock.
14 Sound system, 24 VDC

Instructions are included.
15 Writing table with light
16 Printer for load printouts
17 Camera with monitor

For improved rearward visibility. The camera is located on the
counterweight and the monitor is located inside the cab.

18 Socket 24 VDC
The socket is located on the right side behind the operator’s seat
and is routed across a fuse.
19 Slip-protection on steps (Not positioned in figure)
Can be equipped with optional slip-protection on tank and
counterweights
20 Steps with rail by cab steps
21 Steps with hand rail by mudguard (Not positioned in figure)

Located on left-hand side.
22 Steps to cab roof
23 Work lights cab roof, 2 lights
24 Work lights front fender, 2 lights
25 Extra work lights front fender, 2 or 4 lights

Replaces headlight front fender.
26 Work lights boom, 2 lights
27 Extra work lights boom, 2 lights

28 Work lights attachment, 2 lights
29 Extra work lights attachment, 2 lights
30 Work lights bottom lift attachment, 2 lights (Not positioned in

figure)
31 Lockable tank cap
32 Tool kit (Not positioned in figure)

Located in battery compartment on left side.
33 Auxiliary heater: (Not positioned in figure)

Equipment kit 1: engine and cab heater
Equipment kit 2: start interlock, engine and cab heater, tank
warmer hydraulics and brake system
34 Pause heater (Not positioned in figure).
35 Central lubrication machine and attachment
36 Elevated air inlet with or without pre-cleaner

37 Extra rotating beacon installed on counterweight (Not positioned
in figure)

3 Overview – 3.2 Plates 29
3.2 Plates
Product plates Europe
page
–
The following shows the product plates that should be fitted on the ma-
chine when operating in Europe. When ordering spare parts and when
enquiring per telephone or correspondence, the model designation
and serial number shall be given according to the plates. The plates’
spare part number is indicated on respective plate.
003672
1, 3 1, 3
1 Machine plate (example), A54516

T = Machine type
M = Machine model
S/N= Serial number/Year of manufacture
Q = Machine’s classed lift capacity acc. to EN1459
W = Machine’s operating weight (without load)
P = Engine power
L = Distance between leading edge of wheels and load’s centre
of gravity
013981
H = Classed lift height

Field H and L indicate how big a load the machine can handle at
a specified attachment height (H) and distance from the ma-
chine’s leading edge (L).
Machine plate can only be ordered with complete engraving.
2 Type plate for attachment (example)
S/N= Serial number/Year of manufacture.
Lower field indicates year of manufacture.
Type plate can only be ordered with complete engraving.
012959

30 3 Overview – 3.2 Plates
3 Additional plate for optional equipment (example)

Plate appearance depends on type of optional equipment. Exam-
ple plate is for machine with support jacks.
M= Machine model.
S/N= Serial number/Year of manufacture.
A= Identification number for attachment.
H= Lift height.
L= Distance from machine’s leading edge (lift capacity).
013982
Plate can only be ordered with complete engraving.

Warning and information plates

–
The following figures show the warning texts and information texts that
are located on the machine. The operator shall be aware of the warn-
ings and should also follow the instructions and information given on
the plates.
Make sure warning and information symbols on the machine and its
components always are easy to see and legible. Plates that have been
damaged, illegible or painted over must be replaced immediately.
1b 1a 1b 23 1b 4 17 1a 1b
18 7 20 23 18 18 21 8 23 13 11 18
5
3
22 24 1a
013964
6 9
2 12 15 14 16,19 10
Frame, cab
1 Lift point, 423049.0100
Attaching point for lifting device when lifting the machine and
boom. For lifting machine (1a):
• front part of frame
000276
• rear part of frame by boom mounting

For lifting boom (1b):
• front part of boom
• rear part of boom
2 Warning! A26939.0200
Emergency lowering, see section 6.2 9 Hydraulic system for
information.
000278

3 Warning! A55488.0100
Emergency cab lowering.
011834
4 Warning! A55488.0300
Lock by height-adjustable cab.
014505 5 Warning! A30536.0300

No passengers allowed. Passengers may only ride in the cab if
it’s equipped with a permanently mounted passenger seat.
000280
6 Warning! A30770.0100
Air conditioning. Filling of refrigerant requires special compe-
tence and authorisation (follow national legislation and local
000281
rules).
7 Warning! A30770.0200
Air conditioning. Located on right frame member.
Filling of refrigerant requires special competence and authorisa-
tion (follow national legislation and local rules).
000282
8 Warning! A54527.0200
Air conditioning. Filling of refrigerant requires special compe-
tence and authorisation (follow national legislation and local
rules).
1 = Refrigerant, type
2 = Amount, kg
1
3 = Pressure, bar
2
014528

9 Plate for non-ionising radiation, A57336.0100
012968
Safety
10 Warning! A32442.0100
Do not jump. Always stay in the machine when there’s a risk of
roll-over and hold on to the steering wheel.
000284
Electrical system
11 Battery disconnector, A30537.0300
In position 0, the battery’s plus terminal is disconnected.
004841
12 Plate battery voltage, A30534.0200

Turn off the battery voltage (with battery disconnector) when re-
moving/installing boom. Otherwise sparks and short-circuiting
may occur.
001979
A30534.0200
Engine
13 Filling point, fuel, 450202.0100
D
000286
450202.0100
14 Warning! A30530.0100
Rotating fan.
000287

15 Warning! A30532.0100
Hot surfaces.
000288
16 Filling point, engine oil, A32439.0500
000289
17 Warning! Filling point, coolant, A57775.0100
Use only ready-mixed recommended coolant.
013692
Power transmission, wheels

18 Air pressure tyres 1.0 MPa, A32049.0100
NOTE
000290
Read chapter 6 Inspection and maintenance regarding safe-

ty when handling wheels.
The conditions for inflation pressure change if factory-fitted
tyres are replaced with another tyre brand! Contact
Cargotec.
19 Filling point, transmission oil, A32439.0200
000291
Brake system
20 Filling point hydraulic oil, 450203.0100
000292

Hydraulic system
21 Pressure hydraulics, A54518 (example below)
Indicates set pressures for the machine. Information is engraved.
014529
22 Warning! A30529.0100
Pressure. Always release the pressure from the accumulators
before working on the hydraulic system.
Work with the hydraulic system shall always be performed by au-
thorised personnel!
000294
Attachment
23 Warning! A30533.0200
Rotating parts.
000853

24 Warning! A32440.0100
Do not walk or stand under a suspended load.
DANGER
The attachment is a tool that handles heavy loads.

ty damage!
000296
Never walk under hanging loads.

4 Instruments and controls 37
4 Instruments and controls
4 Instruments and
mm mm mm mm mm mm
controls
General
page
–
Do not operate the machine before you know the position and function
of instruments and controls, and completely understand how they are
used!
This chapter gives general information about instruments, switches,
controls and other equipment in the machine’s cab.
NOTE
Thoroughly read the following chapter about instruments and
controls.

38 4 Instruments and controls
Overview
–
1 2 3 4 5
15
12 13 12 11 10 9 8 7 6
006457
14
Overview
1 Left instrument panel
2 Gear selector and multi-function lever
3 Steering wheel panel
4 Steering wheel
5 Direction indicators
6 Panel for hydraulic functions
7 Control breaker for hydraulics
8 Switch for parking brake
9 Control lever
10 Driver’s seat
11 Accelerator
12 Brake pedals
13 Clutch pedal
14 Electronic box with fuses and relays
15 Hour meter (operating hours)
A Joystick or mini steering wheel

Instrument panel
16 Switch for fan
17 Switch for heat
18 Switch for air distribution
29 30 31 19 Switch, work lights cab roof
24..28
20 Switch, work lights attachment
19..23
21 Switch, work lights boom
18
17 22 Switch, revolving beacon
006456
16 23 Switch for flashing hazard lights
Instrument panel 24 Switch for headlights
25 Switch for seat heating
26 Switch for electrically heated rear view mirrors

27 Spare
28 Switch for pause heater

29 Spare
30 Spare
31 Socket 12 VDC

40 4 Instruments and controls
Steering wheel panel

32 Warning light, low battery charging
36
35 33 Warning lamp for low brake pressure
34
33 34 Indicator light for active error codes
32
35 Warning lamp, by-pass of hydraulic functions
36 Indicator light, activated steering with joystick or mini-wheel

37 Warning lamp, high coolant temperature
37..41 49
38 Warning lamp, low oil pressure in engine
42..46 39 Indicator light for preheating
47 48 40 Warning lamp for low coolant level engine
41 Warning lamp, high oil temperature in transmission
42 Warning lamp, low fuel level
50 51 52 53 43 Warning lamp, high temperature hydraulic oil
44 Indicator light, high beams
45 Indicator light for direction indicators
46 Indicator light, parking brake
47 Indicator light, locked twistlocks (secured load)
48 Indicator light, alignment (attachment / load)
49 Indicator light, unlocked twistlocks (load released)
64
54 50 Panel, warning and indicator lights
63 51 Control system display
55
62 52 Control system indicator
56
005073
61 60 59 58 57 53 Ignition
54 Switch for defroster
Steering wheel panel with panel for warning and
55 Switch, windscreen wiper roof, interval
indicator lights
56 Switch, windscreen wiper roof, continuous
57 Switch, interior lighting
58 Switch, windscreen wiper rear, interval
59 Switch, windscreen wiper rear, continuous
60 Control system function keys
61 Travel direction indicator, Forward Neutral Reverse
62 Switch, shifting program A, Automatic shifting
63 Switch, shifting program 1, locked to 1st gear
64 Switch, shifting program 2, locked to 2nd gear

Panel for hydraulic functions
65 Switch, bottom lift attachment, front legs

65 66 67 68
66 Switch, bottom lift attachment, rear legs
67 Switch, rotation stop
69..72 Switch, height limitation
Switch, LC-limitation (load centre)
73 68 Switch, automatic cab tilt
74 69 Switch, twistlocks, automatic/manual locking

76
75 70 Switch, bottom lift attachment, clamping position
006454
Switch for lowering overheight legs
Panel for hydraulic functions
71 Switch for 30’ stop
72 Switch, hydraulic sliding cab
Switch, hydraulic vertically adjustable cab
Switch, hydraulic cab tilt
73 Indicator light, support jacks
74 Switch, support jacks
75 Switch for automatic spreading 20’ to 40’

76 Switch, by-pass of hydraulic functions

42 4 Instruments and controls – 4.1 Warning and indicator lights
4.1 Warning and indicator lights

General
page
–
This section describes the warning lamps and indicator lights in the
cab. They indicate the status of sub-systems/systems. An illuminated
warning lamp should be attended to immediately. An illuminated indi-
cator light informs of imminent action.
All lights in the panel are activated briefly at start. Warning and indica-
tor lights are concentrated in a panel on the steering wheel panel
(position 50).
Numbers in brackets refer to the positions in Overview page 38.
Warning lamp, low battery charging (32)

–
The light (red) warns in case of missing charge to the batteries. The
light is activated if the voltage from the alternator is lower than the bat-
tery voltage.
000297
If the warning light remains lit, switch off the engine and contact
service.
NOTE
Do not operate with an activated light for low battery charging.
Warning lamp, low brake pressure (33)

–
The light (red) is activated when the pressure in the accumulator, that
is, the brake pressure is too low. After the light has been activated, the
service brake’s capacity is limited.
000298
Check the sealing integrity of the accumulators if pressure is not built

up and maintained, see chapter 6 Inspection and maintenance.
Indicator light for active error codes (34)

–
The indicator light (orange) shows that the control and monitoring sys-
tem has one or several error codes, active or passive. For more infor-
mation, see section 5.3 Error codes.
000299
The indicator light is activated for as long as there are active error
codes (STOP, WARNING or INFORMATION).
Warning lamp, by-pass (35)

–
The warning lamp (orange) shows that bypass of safety functions for
hydraulics is in progress.
000300
NOTE
By-pass can only continue for 60 seconds at a time.

4 Instruments and controls – 4.1 Warning and indicator lights 43
Indicator light, activated joystick or mini steering

–
wheel (36)
The indicator light (green) lit when joystick steering or mini-wheel

steering is activated.
000301
Warning lamp, high coolant temperature (37)
–
The light (red) is activated if engine coolant temperature is too high.

Determine the cause and take appropriate action.
000302
If the warning light remains lit, switch off the engine to allow the coolant
to cool. If the indicator remains lit when the machine is restarted, con-
tact service.
For engine alternative Volvo TAD1250VE and Volvo TWD1240VE:
Very high coolant temperature leads to engine shutdown.
Warning lamp, low oil pressure in engine (38)

–
If the light (red) is activated during operation, pressure is very low.

Stop the engine immediately. Determine the cause and take appropri-
ate action. Contact service.
000303
For engine alternative Volvo TAD1250VE and Volvo TWD1240VE:

Very low oil pressure in engine leads to engine shutdown.
Indicator light, preheating (39)

–
For engine alternative Volvo TAD1250VE and Volvo TWD1240VE.

The light (orange) is activated during the engine’s preheating period.
When needed, preheating warms the engine’s inlet air to a suitable
temperature with a heating coil when the ignition is in position II.
000304
When needed, the engine’s control unit activated preheating during a

time period.
Engine can be started, position III (start position), regardless of if pre-
heating is in progress, not activated (no need) or has been finished.
Warning lamp, low coolant level engine (40)

–
If the light (red) is activated while operating, the coolant level is too
low. Check and top up, if needed. For action, see chapter 6 Inspection
and maintenance.
000305
For engine alternative Volvo TWD1240VE: If there is no coolant in the

expansion tank, the engine turns off. The engine can be started and
run for another 20 seconds before the engine shuts off again.
Warning lamp, high oil temperature in

–
transmission (41)
The light (red) is activated if the transmission oil temperature is too
high. Stop the machine and let the engine run at idle speed. Determine
the cause and take appropriate action. Contact service.
000306

44 4 Instruments and controls – 4.1 Warning and indicator lights
Warning lamp, low fuel level (42)

–
The light (orange) indicates when the fuel level is low. The machine
should be refuelled as soon as possible. For action, see chapter 6 In-
spection and maintenance.
000307
Approx. 10% of the fuel remains, which corresponds to approx.
3 hours operating time, when the light is first activated.
Warning lamp, high temperature hydraulic oil

–
(43)
The light (red) is activated if the hydraulic oil temperature is too high.
Stop the machine and let the engine run at idle speed. Determine the
000308
cause and take appropriate action. Contact service.
Indicator light, high beams (44)

–
The light (blue) is activated when the high beams are on.
000309
Indicator light, direction indicators (45)

–
The lamp (green) flashes when the direction indicators or hazard lights
are on.
000310
Indicator light, parking brake (46)

–
The light (red) is activated when the parking brake is applied.

If the indicator light flashes, the parking brake has been applied auto-
000311
matically (not by the operator) when the machine has stopped. To re-
lease the parking brake, turn on and turn off the parking brake with the
switch for parking brake (position 8).
Indicator light for locked twistlocks (47)

–
The indicator light (green) is activated when the twistlocks are locked
and the load is secured.
000312
Indicator light, alignment (48)

–
The indicator light (orange) is activated when the attachment has

alignment with the load.
000313
Indicator light for unlocked twistlocks (49)

–
The indicator light (red) is activated when twistlocks are unlocked and
the load is released.
000314

4 Instruments and controls – 4.1 Warning and indicator lights 45
Indicator, control and monitoring system (52)

–
The indicator light (red) alerts the operator. It illuminates if there is

event-controlled information or and flashes when a STOP or
WARNING error code is shown on the control system display.
000402
See section 4.11 Control system for detailed information.
Travel direction indicator, Forward Neutral

–
Reverse (61)
The letters F (Forward), N (Neutral) or R (Reverse) are activated for
each respective travel direction.
000403
Indicator light, support jacks (73)
–
The indicator light (green) is activated when the support jacks are
completely lowered.
000315

46 4 Instruments and controls – 4.2 Instruments
4.2 Instruments
General
page
–
This section describes the analogue instruments in the cab. The gaug-
es or digits indicate levels/status of systems.
Hour meter (15)

–
The hour meter shows the number of hours that the engine has been
running.
The meter is used to determine when the machine is due for periodic
maintenance. All times in periodic maintenance are based on the ma-
chine’s operating time in hours.
001342

4 Instruments and controls – 4.3 Ignition 47
4.3 Ignition
General
page
–
This section describes the ignition key lock (position 53).

Ignition’s function
–
P No function.
0 Stop position. Ignition off, i.e. everything is switched off.
The key can be removed.
I Operating position.
Current to all electrical functions. Control units for engine
and transmission are now active.
II For engine alternative Volvo TAD1250VE and Volvo
TWD1240VE: Preheating mode
Preheating warms the engine’s inlet air to a suitable tem-
perature with a heating coil. The light for preheating (posi-
tion 39) indicates if preheating is activated.
When needed, the engine’s control unit activated preheat-
0 ing during a time period.
P Engine can be started, position III (start position), regard-

I
less of if preheating is in progress, not activated (no need)
or has been finished.
For engine alternative Cummins QSM11: No function
II
III Start position.
Engagement of starter motor for engine start.
000317
III The engine should not be started (key to start position) until
the warning and indicator lights, see Overview page 38,
have completed start-up mode (light and go out again).
Note that a light may remain lit to indicate status.
NOTE
The machine is equipped with an electric restart inter-
lock, which prevents engagement of the starter motor
when the engine is rotating.
Condition for starter motor to engage is that the trans-
mission is in neutral position and that the engine isn’t
already running.

48 4 Instruments and controls – 4.4 Switches
4.4 Switches
General
page
–
This section describes the switches in the cab. Each switch controls a
function. Contrast for background lighting is adjusted with the function
keys "-/4" and "+/5" for the control and monitoring system.
Control breaker for hydraulics (7)

–
Switch for control breaker cuts off electric power to all load handling
functions. Reset by turning the switch clockwise.
002084
Switch for parking brake (8)

–
Switch (red) for applying parking brake.

Position 0 – Parking brake off.
002206
Position 1 – Parking brake on.

0 1
Switch for fan (16)
–
For description, see Heating / Air conditioning page 69.

004686
1 0 2
Switch for heat (17)
–

004687
1 0 2
Switch, height limitation (18)
–

004688
1 0 2
Switch for work lights cab roof (19)
–
Switch (orange) for work lights on the cab roof as well as optional work
lights on front fender. Also activates tail lights and side running lights.
Work lights are turned off after idling for 5 minutes, extra work lights
000318
after 2 minutes. Work lights are turned on again at throttle application,

0 1 gearshifting or activation of any load handling function.
Position 0 – Lights off.
Position 1 – Lights on.

4 Instruments and controls – 4.4 Switches 49
Switch for work lights attachment (20)

–
Switch (orange) for work lights on the attachment. Also activates rear
lights and side running lights.
000319
0 1
gearshifting or activation of any load handling function.
Switch for work lights boom (21)

–
Switch (orange) for work lights on the boom. Also activates rear lights
and side running lights.
000320
0 1
gearshifting or activation of any load handling function.
Switch for revolving beacon (22)

–
Switch (green) for revolving beacon used to attract attention in con-

nection with hazards.
Position 0 – Revolving beacon off.
000321
0 1 Position 1 – Revolving beacon on.
Switch for flashing hazard lights (23)

–
Switch (red) for flashing hazard lights used to attract attention in con-
nection with parking hazard.
Position 0 – Flashing hazard lights off.
000322
0 1 Position 1 – Flashing hazard lights on.
Switch for headlights (24)

–
Switch (green) for headlights. Also activates rear lights and side run-
ning lights.
Position 0 – Headlights off.
000323
0 1 Position 1 – Headlights on.
Switch for seat heating (25)

–
Switch (orange) for seat heater. Switch may be located on the seat.
Position 0 – Seat heater off.
Position 1 – Seat heater on.
000324
0 1

Switch electrically heated rear-view mirrors (26)

–
Switch (green) for electrical heating of rear-view mirrors (position 26).

Position 0 – Heating of rear view mirrors off.
006057
0 1
Position 1 – Heating of rear view mirrors on (symbol lit).
Switch for pause heater (28)

–
004922
0 1
Switch for defroster (54)
–

003470
Switch, windscreen wiper roof, interval (55)

–
Switch (green) for windscreen wiper on roof window. Interval wiping.

Interval wiper is activated/deactivated with press of a key. Time inter-
000326
val for wiping is controlled by windscreen wiper front windscreen.
NOTE
The interval is controlled by the interval selected for the
windscreen.
Switch, windscreen wiper roof, continuous (56)

–
Switch (green) for windscreen wiper on roof window. Continuous

wiping.
000327
Wiper is activated/deactivated with press of a key.
Switch, interior lighting (57)

–
Switch (green) for interior lighting in cab.

Lighting is activated/deactivated with press of a key.
000330
Switch, windscreen wiper rear, interval (58)

–
Switch (green) for windscreen wiper on rear window. Interval wiping.

Interval wiper is activated/deactivated with press of a key. Time inter-
000328
val for wiping is controlled by windscreen wiper front windscreen.
NOTE
The interval is controlled by the interval selected for the
windscreen.

Switch, windscreen wiper rear, continuous (59)

–
Switch (green) for windscreen wiper on rear window. Continuous

wiping.
000329
Wiper is activated/deactivated with press of a key.
Switch for shifting program A (62)

–
Switch (green) for selecting shifting program A, automatic shifting.

Active shifting program is indicated with a light-emitting diode.
000413
Switch for shifting program 1 (63)
–
Switch (green) for selecting shifting program 1, which means that gear
position is locked to 1st gear.
000414
Switch for shifting program 2 (64)

–
Switch (green) for selecting shifting program 2, which means that gear
position is locked to 2nd gear.
000415
Switch, bottom lift attachment, front legs (65)

–
Switch (green) controls the front legs on the bottom lift attachment.
The front legs hold the load together with the rear pair of legs. Rocker
switch.
000405
Position 1 – Front legs are lowered. Switch must be pressed down dur-
1 0 2
ing the entire movement.
Position 0 – Legs are stationary.
Position 2 – Front legs are raised. Switch must be pressed down dur-
Switch, bottom lift attachment, rear legs (66)

–
Switch (green) controls the rear legs on the bottom lift attachment. The
rear legs hold the load together with the front pair of legs. Rocker
switch.
000406
Position 1 – Rear legs are lowered. Switch must be pressed down dur-
1 0 2
Position 2 – Rear legs are raised. Switch must be pressed down during
the entire movement.

Switch for rotation stop, height limitation and

–
LC-limitation (67)
Switch (green) activates by-pass of rotation stop, height limitation and

LC-limitation (load centre), see section 5.5.4 Functions for load
handling.
000331
Position 0 – Attachment can rotate ±25°, lift height limited and LC-lim-
0 1
itation active.
Position 1 – Rotation stop is by-passed and free rotation of attachment
is possible, free lift height and LC-limitation not active.
Switch, automatic cab tilt (68)

–
Switch (yellow) for automatic/manual cab tilt.

This switch is used to select whether the cab should be tilted automat-
ically or manually.
004464
0 1 Position 0 – Automatic cab tilt. The cab is tilted automatically when the
attachment is at a certain lifting height.
Position 1 – Manual cab tilt. The cab is tilted using the switch for hy-
draulic cab tilt position 72.
Switch, twistlocks, automatic/manual locking

–
(69)
Switch (green) for locking twistlocks. The switch has a rocker function
in position 2.
Position 1 – Twistlocks are locked automatically when there is align-
000408
ment with the load. The parking brake must be OFF, see position 8
1 0 2
and indicator light for parking light, position 46.
Position 0 – Locking of twistlocks not activated.
Position 2 – Twistlocks are locked manually. Rocker switch.
Switch, bottom lift attachment, clamping

–
position (70)
Switch (green) controls clamping position of the leg pairs on the bot-
tom lift attachment. Rocker switch.
Position 1 – Leg pairs release load. Switch must be pressed down dur-
000409

1 0 2
Position 2 – Leg pairs clamp around the load. Switch must be pressed
down during the entire movement.

Switch for lowering overheight legs (70)

–
The switch (green) controls the legs on a top lift attachment with over-
height legs. Each leg has a twistlock which must all indicate unlocked
twistlocks, see indicator light for unlocked twistlocks position 49, to en-
able operation of the legs. Rocker switch.
006496
1 0 2
Position 1 – Legs are lowered. Switch must be pressed down during
Position 2 – Legs are raised. Switch must be pressed down during the
entire movement.
Switch for 30’ stop (71)

–
Switch (green) for 30’ stop. This function is used to adapt the attach-
ment’s spreading to container size (need adaptation). Distance for
30-35
spreader stop is preset in control unit.
000410
Damping is activated shortly before preset value for stop. To continue

0 1
spreading, perform continuous spreading function once again with the
control lever to desired position (end-position is 40’).
Position 0 – Spreading stop not activated.
Position 1 – Spreading stop activated. During spreading in progress,
automatic stop takes place at 30’.
Switch, hydraulic sliding cab (72)

–
Switch (green) for hydraulic sliding cab. Rocker switch. The operator’s
door(s) must be closed and the control breaker for hydraulics not
activated.
000332
Position 1 – Cab slides forward. Switch must be held depressed during

1 0 2
Position 0 – Cab is stationary.
Position 2 – Cab slides rearward. Switch must be held depressed dur-
NOTE
The cab can only be moved if the doors are closed.

Switch, hydraulic vertically adjustable cab (72)

–
Switch (green) for hydraulic vertically adjustable cab. Rocker switch.

The operator’s door(s) shall be closed and the control breaker for hy-
draulics not activated.
001613
Position 1 – Cab is lifted. Switch must be pressed down during the en-
1 0 2
tire movement.
Position 2 – Cab is lowered. Switch must be pressed down during the
entire movement.
NOTE
The cab can only be moved if the doors are closed.
Switch, hydraulic cab tilt (72)

–
Switch (green) for hydraulic cab tilt. Rocker switch. The operator’s
door(s) must be closed and the control breaker not activated.
Position 1 – Cab tilts down. Switch must be pressed down during the
004664
entire movement.
1 0 2
Position 2 – Cab tilts up. Switch must be pressed down during the en-
tire movement.
NOTE
The cab can only be tilted with closed doors and that boom height
(boom angle) gives room for safe cab tilt.
Move the cab while the machine is stationary!
Switch, support jacks (74)

–
Switch (green) for support jacks. Rocker switch. The parking brake
must be OFF, see position 8, and indicator light for parking light,
position 46.
000404
Position 1 – Support jacks are lowered. Switch must be pressed down

1 0 2
during the entire movement. The indicator light for support jacks is ac-
tivated when the legs are down (position 73).
Position 0 – Support jacks are stationary.
Position 2 – Support jacks are raised. Switch must be pressed down
during the entire movement.

Switch for automatic spreading 20’ to 40’ (75)

–
Switch (green) for automatic spreading of attachment to 40’. This func-

tion is used to give automatic spreading of attachment at instantane-
ous function selection with the control lever.
000411
Damping is activated shortly before any spreading stop (function for
0 1
30’ stop must be activated). To continue spreading to end-position 40’,
perform instantaneous function selection with the control lever.
A buzzer in the boom nose sounds at automatic spreading. To cancel
an on-going automatic 20’ to 40’ spreading, activate spreading in or
out with the control lever.
Position 0 – Automatic spreading 20’ to 40’ not activated.
Position 1 – Automatic spreading 20’ to 40’ activated. Is function for 30’
stop activated, spreading stop takes place.
NOTE
Automatic spreading can only be activated with closed doors and
released parking brake.

Switch for by-passing (76)

–
Switch for by-passing various functions. Rocker switch, can only be

activated for 60 seconds.
Position 0 – By-pass not activated.
Position 1 – By-pass activated.
By-passing the safety system allows:
• lowering of load in case of overload
0 • locking and opening of twistlocks without full contact
1 • extension (spreading) 20’–40’ with locked twistlocks
• bottom lift without complete alignment
006854 • selection of gear without the sensor in the operator’s seat indicat-
ing that someone is sitting in it.
WARNING
Safety features are blocked.
No safety system is activated! Risk of roll-over and

tipping over!
Only use bypass in emergency situations!

4 Instruments and controls – 4.5 Gear selector and multi-function lever 57
4.5 Gear selector and

multi-function lever
General
page
–
This section describes the functions of the gear and multi-function

lever. (position 2).
Shifting program and travel direction

–
Shifting program and travel direction are selected with the gear and
F multi-function lever.
Selecting direction of travel:
• F – Forward
• N – Neutral
• R – Reverse with back-up alarm (acoustic warning signal). The
back-up light is activated as long as R is engaged.
Three different shifting programs can be selected with the following
R switches on the steering wheel panel (position 3):
• 2 – Shifting locked in 2nd gear (position 64)
• 1 – Shifting locked in 1st gear (position 63)
• A – Automatic shifting (position 62)
000337
Headlight control and horn

–
Headlights and horn are controlled with the gear and multi-function
lever.
• With headlights on: Gear and multi-function lever is used to switch
between high and low beams. Move the control towards yourself
to switch between high and low beams, and back.
• With headlights off: Gear and multi-function lever is used to flash
000339
A
with the headlights. Move the control toward yourself for high
beam flash, return is automatic.
A. Horn
• Push button for horn (position A).

58 4 Instruments and controls – 4.5 Gear selector and multi-function lever
Windscreen wiper and washer

–
Windshield wipers and washer are controlled with the gear and multi-
2 function lever. Turn the control to the following positions:
3 1
0 • 0 – No wiping front windshield. Controls slow interval wiping for
roof window and rear window if switch for roof window
(position 55) and/or rear window (position 58) is activated.
• 1 – Slow interval wiping front windshield. Controls slow interval
wiping for roof window and rear window if switch for roof window
000338
(position 55) and/or rear window (position 58) is activated.
• 2 – Fast interval wiping front windshield. Controls fast interval wip-
ing for roof window and rear window if switch for roof window (po-
sition 55) and/or rear window (position 58) is activated.
• 3 – Continuous wiping, front windshield. Controls fast interval wip-
ing for roof window and rear window if switch for roof window (po-
sition 55) and/or rear window (position 58) is activated.
• Push the control toward the – steering wheel. Washing of wind-
shield. Controls washing of windshield and rear window if switch
for roof window (position 55 or 56) and/or rear window (position 58
or 59) is activated. Wiping goes temporarily to continuous wiping
when washing windshields.
Wiper function stops after two minutes if the operator leaves the seat.
The wiper function is reactivated when the operator sits in the seat
again and throttles up, selects a gear or uses any hydraulic function
from the control lever.

4 Instruments and controls – 4.6 Control lever 59
4.6 Control lever

General
page
–
This section describes the functions of the control lever (position 9).
Several hydraulic functions are controlled by switches.
It’s possible to vary the speed of the different hydraulic functions, i.e.
lift, lower, etc., by varying the extent of the lever deflection. It’s also
possible to vary the speed of the hydraulic functions with the engine
speed (rpm).
30-35
WARNING
In the event of an emergency! In the event of unde-
30-35
sired activation/movement of a function.
Risk of personal injury and/or property damage!
IMMEDIATELY TURN OFF all working hydraulics by

pressing the CONTROL BREAKER for hydraulics
006770
(position 7).
9 7
7. Control breaker for hydraulics
9. Control lever NOTE
For hydraulic vertically adjustable cab: The doors shall be closed
or the cab in the bottom (lowered) position, otherwise all functions
are disconnected.
For hydraulic sliding cab: The doors must be closed or the cab in
the rear position, otherwise all hydraulic functions are
disconnected.

60 4 Instruments and controls – 4.6 Control lever
Functions, control lever

–
1 2a 3 4
2b
5 6
7 8 9 10
000333
1. Variable tilt, attachment
2. Locking of:
a. tilt
b. levelling
3. Rotation, attachment
4. Side shift, attachment
5. Synchronised lift
6. Boom out or in
7. Hydraulic levelling attachment

8. Extension (spreading) attachment 20’-40’
9. Release of twistlocks
If there is no alignment, the button controls the horn.
10. Lift or lower boom

4 Instruments and controls – 4.6 Control lever 61
Light panel on boom for top lift attachment

–
There is a light panel on the boom that is helpful when handling loads
A B C with the top lift attachment. The panel uses coloured lights to indicate
if and when twistlocks are locked/unlocked, that is, if the load is se-
cured/not secured.
A Twistlocks locked (load secured), green.

B Alignment attachment’s four corners, orange.
C Twistlocks unlocked (load not secured), red.
D Overheight legs raised, white.
D 006497
Light panel on boom, top lift attachment

Light panel on boom for bottom lift attachment
–
There is a light panel on the boom that is helpful when handling loads
A B C with the bottom lift attachment. The panel uses coloured lights to indi-
cate if and when the legs have alignment and clamping position, that
is, when the load is secured/not secured.
A Twistlocks locked (load secured), green.

B Alignment attachment’s four corners, orange.
C Twistlocks unlocked (load not secured), red.
E H
D Alignment left leg front, green.
E Alignment right leg front, green.
D I F Alignment left leg rear, green.
G Alignment right leg rear, green.
F K H Clamping position front leg pair, orange.
000416
G I Front leg pair raised, white.

J
Light panel on boom, bottom lift attachment J Clamping position rear leg pair, orange.
K Front leg pair lowered, orange.
NOTE
Lights D, E, F and G must be activated within 4 seconds when lift-
ing, otherwise the lift attempt is aborted. Lower load to the
ground. Lights D, E, F, G, H and J must be unaffected before a
new lift attempt is made.

62 4 Instruments and controls – 4.7 Pedals
4.7 Pedals
General
page
–
This section describes the machine’s foot-operated functions.

000340
12 13 12 11
11. Accelerator
12. Brake pedal
13. Clutch pedal
Accelerator (11)
–
The accelerator pedal (position 11) is electronic and controls the

injectors.
For the hydraulic functions lift/lower boom and boom in/out, with the
machine declutched or gear in neutral, the system gives automatic
throttle increase for higher hydraulic power.
Brake pedals (12)

–
The brake pedals (position 12) are mechanical and are connected to
the separate hydraulic that makes up the brake system. The brake
pedals are used for service brake.
The accumulators ensure that there’s always brake pressure availa-
ble, even in case of a temporary engine stop. If the accumulator pres-
sure drops below a certain level, the warning lamp for low brake
pressure (position 33) is activated.
Clutch pedal (13)

–
The brake pedal is combined with a separate clutch pedal

(position 13). The pedal is used to disengage the transmission, which
makes it possible to use the hydraulic functions when a gear is
engaged.

4 Instruments and controls – 4.8 Steering wheel 63
4.8 Steering wheel

General
page
–
This section describes controls for steering. The following alternatives

are available for steering the machine:
• steering wheel (position 4) with either fixed or adjustable steering
wheel shaft .
• joystick (position A)
• mini steering wheel (position A)

Steering wheel
–
Clockwise rotation of the steering wheel steers the machine to the

right, and vice versa.
The steering wheel’s and instrument panel’s angle and height can be
adjusted to the desired operating position.
1. Steering wheel’s height.
1
To adjust: Move upper lever upward.
2. Steering wheel panel’s angle.
To adjust: Move upper lever downward.
3. Steering column’s angle.

2 To adjust: Loosen the lower handle and adjust to desired position.
Tighten the handle securely after adjusting.
3
000341
Adjustment possibilities for steering wheel

64 4 Instruments and controls – 4.8 Steering wheel
Joystick
–
Joystick steering is an electro-hydraulic system, mounted in the left

3 4
armrest, to steer the machine using a joystick. When the joystick is
2 moved to the right, the machine steers right, and vice versa. The steer-
ing angle is inversely proportional to the machine’s speed, that is, low
speed gives greater wheel angle, and vice versa.
1 The standard steering wheel is equipped with sensors that detect
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steering
wheel, the joystick is disconnected. The indicator light for activated
joystick or mini-wheel steering (position 36) goes out on the panel for
warning and indicator lights.
1. Joystick.
2. Travel direction selector F/N/R.
forward = F
5 middle position = N
reverse = R
3. Button for engaging joystick steering.
Conditions: Machine speed must be below 3 km/h. If speed is over
3 km/h, joystick steering cannot be engaged. Indicator light for ac-
tivated joystick or mini-wheel steering (position 36) is activated on
the panel for warning and indicator lights when joystick steering is
000900
engaged.
4. Sound signal.
5. Arm rest.

4 Instruments and controls – 4.8 Steering wheel 65
Mini steering wheel

–
The mini steering wheel (mini-wheel) is an electro-hydraulic system,

3 4
mounted in the left arm rest, to steer the machine using a small steer-
ing wheel. Clockwise rotation of the mini-wheel steers the machine to
2
the right, and vice versa. The ground wheels always follow the mini
steering wheel’s position. If the mini-wheel is released, both the mini-
1 wheel and the ground wheels remain in the set position.
The standard steering wheel is equipped with sensors that detect
eventual steering wheel movements in case of an emergency situa-
tion. As soon as the operator starts to steer with the standard steering
wheel, the joystick is disconnected. The indicator light for activated
joystick or mini-wheel steering (position 36) goes out on the panel for
warning and indicator lights.
1. Mini steering wheel.
The steering wheel’s position on the arm rest is adjustable.
2. Travel direction selector F/N/R.
5
forward = F
middle position = N
reverse = R
3. Button for engaging the mini steering wheel.
Conditions: Machine speed must be below 3 km/h. If speed is over
3 km/h, mini-wheel steering cannot be engaged. Indicator light for
000583
activated joystick or mini-wheel steering (position 36) is activated

on the panel for warning and indicator lights when mini-wheel
steering is engaged.
4. Sound signal.
5. Arm rest.

66 4 Instruments and controls – 4.9 Driver’s seat
4.9 Driver’s seat

General
page
–
This section describes the operator’s seat (position 10). The following
alternative seats are available:
• Driver’s seat Bege. The seat is equipped with:
• mechanical adjustment
• air suspension
• seat belt
• head restraint
• armrest left
• seat heat
• Driver’s seat Isringhausen. The seat is equipped with:
• mechanical adjustment
• air suspension (external compressor)
• air-adjusted lower back (lumbar) support
• seat belt
• seat heat
• head rest
• armrest left

4 Instruments and controls – 4.9 Driver’s seat 67
Driver’s seat Bege

–
The driver’s seat (position 10) is equipped with several controls for ad-
justment as follows (adjusting is easier when nobody is sitting in the
seat):
1. Distance to pedals.
7 4
Release the seat with the lever and move the seat forwards or
backwards.
2. Height of seat.
Mechanical elevation of seat height:
Turn the knob clockwise or anticlockwise until desired height is
obtained.
Air suspension elevation of seat height:

Turn the knob anticlockwise to lower seat height. Turn the knob
clockwise to elevate seat height. The suspension adjusts auto-
matically to the operator’s body weight.
6 Exiting the cab is easier if the air is let out of the suspension. Pull
the control to the outermost position (seat drops to lowest level).
When entering the cab, press in the control to the innermost posi-
tion (seat elevates to pre-set level).
3. Back rest angle.
1 2 5 3 Turn the knob until desired position is obtained.
4. Armrest right angle.
5. Variable angling of seat and back.
000342
Turn the knob until desired position is obtained.

Driver’s seat with adjustment possibilities 6. Adjustment of suspension travel in two steps (lever located on
back of seat):
Suspension active – Lever against seat’s centre line. Used during
normal operation.
Suspension locked – Lever against seat’s outside. Can only be
done when seat’s height reaches a locked position. Used when
suspension is not desired.
7. Lower back (lumbar) support.
Turn knob until desired firmness in lumbar support is obtained.

68 4 Instruments and controls – 4.9 Driver’s seat
Operator’s seat Isringhausen 6800

–
The driver’s seat (position 10) is equipped with several controls for ad-
justment as follows (adjusting is easier when nobody is sitting in the
seat):
1. Distance to pedals.
Release the seat with the lever (1) and move the seat fore or aft.
To lock the seat, release the lever.
2. Adjusting the seat cushion.
Lift control (2) and adjust the seat forwards or backwards.
3. Lowering seat height.
Lift the control (3) to lower the seat. The seat remains in the lower
position.
11 Press down control (3) to raise seat to previous position.

12 4. Seat cushion angle.
Lift control (4) and adjust the angle by loading/unloading the front
part of the seat cushion.
5. Raising seat height.
10 Lift control (5) to raise the seat, infinitely variable.
Press down control (5) to lower the seat, infinitely variable.
When the desired height is obtained, release the control.
34 567 6. Back rest angle.

006492
9 8 2
Lift control (6) and adjust the angle by loading/unloading the
backrest.
7. Adjusting the damping.
Lift control (7) for maximal damping.
Press down control (7) for minimal damping.
8. seat heat.
Thermostat-controlled heat for seat and back rest.
Press down the button for activation/deactivation. Activated seat
heat is indicated with light in the switch.
9. Plane damping.
Slide the control to the right and left, respectively, to activate/de-
activate level damping.
10. Lumbar support. Integrated pneumatic system.
Press the button to fill and drain, respectively, the air chambers for
optimal body adaptation of the backrest.
11. The armrest angle is infinitely variable with the knob.
12. Arm rest left

4 Instruments and controls – 4.10 Heating / Air conditioning 69
4.10 Heating / Air conditioning

General
page
–
This section describes the function of:

A
• The heating system, EHC, is automatic and has thermostat-con-
trolled control of heat and fresh air.
• Air conditioning system, ECC. Automatic with thermostat-

controlled control of cooling and heating as well as air drying.
The heating system / air conditioning draws heat from the engine’s
cooling system and provides heat when the engine is warm. Cooling
performance is generated by the AC compressor (for ECC).
The system is controlled by fan, heat and air distribution as well as
function for recirculation and defroster:
• Fan speed is adjusted with switch for fan (position 16).
• Heat (and cooling performance for ECC) is controlled with switch
18 for heat (position 17).
17 • Air distribution to the cab is adjusted with switch for air distribution
(position 18). The fresh air inlet is provided with a filter and can be
004690
16
equipped with a fine-filter against pollen (fan’s capacity is
A. Panel nozzle reduced).
16. Switch for fan
• Recirculation of cab air is activated/deactivated by pressing on the
17. Switch for heat
function key for Enter by the operating menu for air conditioning.
18. Switch for air distribution
• Defroster for fast demisting of windows is activated/deactivated
with the switch for defroster (position 54).
NOTE
Operator’s door and windows shall be closed for satisfactory
function of the system.
For ECC: In case of open door, the air conditioning’s AC com-
pressor is turned off (cooling function and air drying stops). Close
the door and the AC compressor is reactivated.
001839
Fresh air inlet for cab

70 4 Instruments and controls – 4.10 Heating / Air conditioning
Operating menu for heating /air conditioning

–
system
The operating menu is shown automatically in the display when switch
for fan, heat or air distribution is activated. This can be selected for
constant display with function keys for arrow right and arrow left.
For detailed description, see Operating menu for heating /air condi-
004916
tioning system page 77.
Switch for fan (16)

–
Switch (green) for fan handles setting of fan speed for the cab.
Setting of fan speed:
004686 • Automatic control, AUTO.
1 0 2 • Manual control in 13 steps from off to max. Fan speed is shown
by the bar’s height in the operating menu for heat / air conditioning
system.
Position 1 – Increases fan speed.
Position 0 – Fan speed unchanged.
Position 2– Reduces fan speed. Activates automatic control, AUTO,
from off.
Operating menu for air conditioning is shown automatically in the dis-
play when switch is used, see Operating menu for heating /air condi-
tioning system page 77. Display stops after 3 seconds if switch is not
used again.
Switch for heat (17)

–
Switch (green) for heat handles setting of reference value for cab tem-
perature. Setting takes place in steps of 0.5 °C.
The temperature range is 16 °C to 27 °C. Setting of min. and max. re-
004687
spectively, switches off automatic climate control (control of fan, heat

1 0 2
and air distribution) and sets the heat valve in min. and max. position,
respectively.
Position 1 – Higher temperature setting. When needed, the cab’s air is
cooled to set temperature (for ECC).
Position 0 – Temperature setting unchanged.
Position 2 – Lower temperature setting. When needed, the cab’s air is
cooled to set temperature (for ECC).
used again.

4 Instruments and controls – 4.10 Heating / Air conditioning 71
Switch, height limitation (18)

–
Switch (green) for air distribution handles distribution of fresh air to the
cab. The air is distributed to the lower parts of the cab (legs), cab
space (panel) and upper cab space (windshield).
004688
Position 1 – Controls air distribution to upper cab space (windshield).
1 0 2
Position 0 – Setting air distribution unchanged.
Position 2 – Controls air distribution to lower cab space (leg).
Recirculation is activated/deactivated by pressing on the function key
for Enter when the operating menu for air conditioning is shown.
used again.
Switch for defroster (54)

–
The switch for defroster, located on the steering wheel panel is used
for fast demisting of the windows. When the defroster is activated the
function controls fan, temperature and damper position.
003470
The defroster is activated/deactivated with a key press or with any of

the other switches for the system. The defroster function is switched
off automatically after 6 minutes.
A symbol for defroster active is shown in display (top right).
Switch for pause heater (28)

–
Switch (green) for pause heater. The cab fan gives heat from the en-
gine’s cooling system during short-term parking of the machine.
Position 0 – Pause heater not activated.
004922
0 1 Position 1 – Pause heater pre-activated. User instruction:

• Park the machine. Keep the engine running.
• Set desired temperature (position 17).
• Press in the switch for pause heater (position 28).
• Turn off the engine, that is, turn off the ignition.
The pause heater is now activated and strives to maintain preset
temperature for the cab.
If the cab temperature falls 6 °C below the preset temperature, the
pause heater stops working since the engine’s cooling system can
no longer deliver the heat required.
NOTE
The higher the preset cab temperature, the shorter the oper-
ating time for the pause heater.

72 4 Instruments and controls – 4.11 Control system
4.11 Control system

General
page
–
This section describes the control system.

50 51 52
The machine is equipped with an electronic system for control and
monitoring of the machine’s different functions.
The system gives the operator information in the form of:
• Error code information
Three levels of error code information can be shown. In case of a
new error code, the indicator for the control and monitoring sys-
tem (position 52) is activated, as well as the indicator light for ac-
tive error codes on the panel for warning and indicator lights
(position 50). See section 5.3 Handling error codes.
• Operating information
Operating information includes, for example, machine speed, en-
gine rpm, fuel level, etc.
006493
• Event-controlled information
60
Event-controlled information is, e.g., alignment and overload.
50. Panel for warning and indicator lights
51. Display for control and monitoring system The information is presented on the steering wheel panel’s display
52. Indicator for control and monitoring system (position 51). The function keys (position 60) are used to navigate in
60. Function keys for control and monitoring system the display menus during, for example, service and troubleshooting.
4.11.1 Operating menus

General
page
–
The operating menu engine and transmission is shown on the display

after starting the machine. Menus are selected with the function keys
1
for right arrow and left arrow. With each press of the key, the display
2
changes to the next menu. To return to the original display, press and
hold in the function key for Reset (R).
This section describes the information that can be obtained from the
different operating menus.
006762
Example of available operating menus

4 Instruments and controls – 4.11.1.1 Operating menu for engine and transmission 73
4.11.1.1 Operating menu for engine and

transmission
Description
page
–
a. Shows current engine speed (rpm).
a c b. Shows current speed in km/h (in display kilometre per hour, kph).
b c. Shows current gear.

d
Travel direction and shifting program are shown on steering wheel
003472
e panel (positions 61-64).
d. Shows current fuel level.
e. Shows current time.
Setting clock
–
1. Go to setting mode by holding in Enter for 3 seconds. Date,

month, year (a) are shown in setting mode.
2. Scroll with <- / -> between hours, minutes, 12/24 h display, date,
month and year.
a
003573
3. Adjust values with +/-.

4. Press Enter at minutes to set seconds to 0.
5. Leave setting mode by pressing Reset.
4.11.1.2 Operating menu for dynamic scale

Description
page
–
The operating menu for dynamic scale is shown in display when lifting
a load (top lift attachment and bottom lift attachment). The load is
weighed regardless of boom position.
c a. Shows weight in tonnes. Accuracy is 1% of load capacity, that is,

b
000357
approx. +/-0.5 tonnes.

b. Shows extension in m from leading edge of front wheel to load
centre.
c. The bar shows loading of the machine in percentage of permitted
load.
4.11.1.3 Operating menu for engine

Description
page
–
a. Shows coolant temperature in °C.
a b. Shows engine oil pressure in bar.

c. Shows oil level (only for engine alternative Volvo TAD1250VE).
b Operating menu shows oil level at engine start. If the oil level
006758
c should drop during operation, this is indicated with an error code

for low oil level engine.
NOTE
Dropping oil level during operation is not shown in this oper-
ating menu.

74 4 Instruments and controls – 4.11.1.4 Operating menu for transmission and hydraulics
4.11.1.4 Operating menu for transmission and

hydraulics
Description
page
–
a. Shows temperature of transmission oil in °C.

b. Shows temperature of hydraulic oil in °C.
a
000356
b
4.11.1.5 Operating menu for container counter

Description
page
–
a. Counter 1 for number of container lifts. Used to count number of

lifts during a work shift.
Reset counter with function key for Enter, select "Reset C1" and
a press function key for Enter to reset counter to zero.
000568
b. Counter 2 for number of container lifts. Used to count the total

b
amount of machine lifts during a selected time period.
Example from operating menu for load handling
Reset counter with function key for Enter, select "Reset C2" and
press function key for Enter to reset counter to zero.
The display indicates which counter has been selected. Press function
key for Reset (R) to return to normal display.
For bottom lift attachment C1 counts number of top lifts and C2

number of bottom lifts.
4.11.1.6 Operating menu for system voltage

Description
page
–
Shows the current system voltage in volt.

000354
Example from operating menu for electrical system

4 Instruments and controls – 4.11.1.7 Operating menu for dynamic scale 75
4.11.1.7 Operating menu for dynamic scale

Description
page
–
a. Shows load’s weight in kilo. Accuracy is 1% of load capacity, that

a
is, approx. +/-500 kg.
b b. Shows extension of boom in centimetres.
c c. Shows extension from centre of front wheel to load centre in cen-
000570
d timetres.
d. Shows boom angle in degrees.
Example from operating menu for dynamic scale
The load is weighed regardless of the boom’s position.
4.11.1.8 Operating menu statistics

Description
page
–
Start display for statistics menu.

003575
Display of statistics
–
Go to display mode by pressing Enter, go back with Reset. Scroll be-

tween the different menus with the function keys for right arrow and left
arrow.
• Operating hours engine (hours).
• Operating hours engine, machine parked and idling (hours).
• Operating hours engine, with gear activated (hours).
• Operating hours hydraulic functions activated (hours).
003697
• Accumulated fuel consumption (litres).

• Fuel consumption (litres).
Press function key for Enter to reset measuring.
• Instantaneous fuel consumption (litres per hour).
006759
• Accumulated driving distance (km).

• Trip meter (km).
Press function key for Enter to reset measuring.
003699

76 4 Instruments and controls – 4.11.1.9 Information menu for printer
• Number of top lifts.

• Number of bottom lifts.
003700
4.11.1.9 Information menu for printer
Description
page
–
The information menu for the printer is a main menu with two sub-men-
us. The main menu is always shown first in the display.
Select the menu "Save weight" with the function key for plus (+). Re-
turn to the main menu with the function key for minus (-).
Select the menu "Print last loads" with the function key for minus (-).
Repeated selection gives printout of several load indications. Return
005070
to the main menu with the function key for plus (+).
Printer in cab
• Print current load (main menu)
a. Indicates current load.
b. Indicates function keys that give selection.
To print the current load, press function key for Enter.
004881
a b
• Save current load

To save the current load, press function key for Enter.
004880
• Print last loads

c. Indicates number of load indications for printout.
Use the function key for plus and minus (+/-), respectively, to indi-
cate the desired number of recent loads for printing (position c).
004882
c Total weight for load is indicated.

To print, press function key for Enter.

4 Instruments and controls – 4.11.1.10 Operating menu for service interval 77
4.11.1.10 Operating menu for service interval

Description
page
–
• Shows total operating time in hours.

• Shows number of hours to next service.
003696
4.11.1.11 Operating menu for service
Description
page
–
Used by service technicians and for showing error codes. For showing
error codes, see section 5.3 Handling error codes.
000056
4.11.1.12 Operating menu for heating /air

conditioning system
Description
page
–
The operating menu is shown automatically in the display when switch

a e for fan, heat or air distribution is activated. This can be selected for
f constant display with function keys for arrow right and arrow left.
b
g Recirculation is activated/deactivated by pressing function key for
c
004689
Enter.
d
a. The bar shows the setting for fan speed, automatic (AUTO) or
Example of operating menu for air conditioning manual control (in 13 steps 0-12).
b. Indicates set reference value for cab temperature.
c. Symbol for setting of fan.
d. Indicates if fan is in AUTO mode.
e. Symbol indicates if defroster is active or not.
f. Arrow shows setting for distribution of fresh air to the cab. Indica-
tion shows toward the lower parts of the cab (legs), cab space
(panel) and upper cab space (windshield).
g. Symbol indicates if recirculation is active or not.

78 4 Instruments and controls – 4.11.2 Event-controlled information
4.11.2 Event-controlled information

General
page
–
The control system draws the operator’s attention to important infor-

mation. The warning/information is shown on the control system’s dis-
play when needed.
Start interlock
–
The menu is shown at start attempt. To start, enter your 5-digit code.
003574
Warning for overload forward

–
The warning figure indicates that the weight on the steering axle is too
low. The lift capacity has reached 100% according to the load curve
for the machine.
Load handling functions are limited and only function for boom in is
allowed.
000358
If the figure is shown, the machine’s load functions are limited:

• Retract the boom to reduce the risk of tipping.
In an emergency situation, the by-pass switch (position 76) can be
used to lower the load
WARNING
No safety system is activated! Risk of roll-over and

tipping over!

4 Instruments and controls – 4.11.2 Event-controlled information 79
Warning for overload on steering axle

–
The warning display means that the load on the steering axle is too
high, which means reduced lateral stability when operating as well as
increased loads on tyres and rims.
In the event of overload on the steering axle, speed is limited dynam-
004910
ically depending on the pressure on the steering axle.
The bar shows current overload on the steering axle. Speed limitation
is activated when the display is shown. Speed limitation is proportional
to the bar’s indication, that is, at MIN permitted speed is higher than at
MAX when the system provides maximum speed limitation.
In case the display is shown (and speed limitation occurs):
• Reduce speed.
• Lower the attachment (to reduce boom angle).
• Move load or attachment forward to reduce pressure on the steer-
ing axle.
NOTE
In case of high load on the steering axle, wear of steering
axle and tyres is high and lateral stability is low.
Alignment top lift attachment

–
The display is shown when one to three corners on the attachment has
contact with the load at alignment. The lift corners that have contact
are filled in. That is, when twistlock ends up in open or locked position.
When all four corner points have contact, the figure disappears and
the load can be locked. Display figure can be removed with function
000360
key for Reset (R).

In case the figure is shown:
• Operate attachment until full alignment is obtained.
Load cannot be secured (lock twistlocks) before full alignment.
The load can be locked when all four corner points have contact.

Alignment bottom lift attachment

–
The figure shows when one to seven sensors on the attachment have
alignment and/or clamping position. Point shows alignment and arrow
shows clamping position for respective lift corner. The lift corners with
contact are filled in.
When correct alignment is obtained and clamping position is active,
000572
the figure disappears and the load can be lifted. Display figure can be
removed with function key for Reset (R).
• Operate the attachment’s legs until full alignment is obtained.
The load cannot be lifted before full alignment. The load can be
lifted for 4 seconds without correct alignment. Then the lift function
is disconnected.
The load can be clamped and lifted when all four lift corners have
contact.
NOTE
When transporting a load with bottom lift attachment, the ma-
chine’s speed is limited to max. second gear and 10 km/h.
Twistlocks
–
The figure is shown when the sensors for twistlocks can’t detect if
twistlocks are in locked or unlocked position. Figure is shown during
lift.
When all sensors have contact, the display figure disappears.
000571

• Operate attachment until full alignment is obtained and twistlocks
are in correct position.
• Open and lock twistlocks (use by-pass if necessary).
Support jacks
–
The display is shown when support jacks are neither in raised nor low-
ered position.
Operate the support jacks up or down, see section 5.5.4 Functions for
load handling. For automatic raising / lowering, throttle up (above
1000 rpm) and press once up / down on the switch for support jacks
000573
(position 74). For automatic raising / lowering, AUTO is shown on

display.
Display figure can be removed with function key for Reset (R).

4 Instruments and controls – 4.11.2 Event-controlled information 81
Height limitation
–
The figure is shown when set maximum lift height has been reached.
Lower or retract boom. The function can be by-passed, see
section 5.5.4 Functions for load handling. Display figure can be re-
moved with function key for Reset (R).
000574
Fixed scale
–
The figure is shown when correct boom extension and key for meas-
uring is pressed in, see section 5.5.4 Functions for load handling. The
load’s weight is calculated by the control and monitoring system.
006761
Open door
–
The figure is shown if:

• doors are not closed for the hydraulic sliding of the cab. The cab
cannot be operated until the doors are closed.
• doors are not closed at function for automatic spreading 20’ to 40’.
000576
Automatic spreading cannot be operated until doors are closed.

• doors are not closed when raising and lowering the cab.
In the event that the figure is shown, close the door(s). Then the figure
disappears. Display figure can be removed with function key for
Reset (R).
Rotation stop
–
The figure is shown when rotation of the attachment reaches allowed

rotation limit ±25° (function for rotation stop limitation is active). When
rotation of the attachment is within the interval for rotation stop limita-
tion, the display figure disappears. The function can be by-passed,
see section 5.5.4 Functions for load handling. Display figure can be re-
001449
moved with function key for Reset (R).
Automatic spreading 20’ to 40’

–
The figure is shown when automatic spreading of attachment 20’ to 40’

is in progress. Display figure can be removed with function key for
Reset (R).
006765

Speed limitation at tilt lock/levelling lock

–
Only for tilt lock/levelling lock

At tilt lock/levelling lock is not suitable to operate the machine at
speeds faster than 5 km/h. This since it gives increased wear. There-
fore, the control and monitoring system limits the machine’s speed.
The figure is shown when the machine’s speed is limited to max.
004911
5 km/h. Reduce speed below 5 km/h or disengage lock function, thus
speed limitation and the display stops. The lock function is handled by
For tilt lock the control lever.
004912 Display figure can be removed with function key for Reset (R).
For levelling lock

5 Handling 83
5 Handling
5 Handling
mm mm mm mm mm mm
General
page
–
The machine is intended to be used in the way that is described in the

operator’s manual. If the machine is used in another way or in poten-
tially dangerous or hazardous conditions, for example, an explosive
environment, special safety regulations must be followed and the ma-
chine must be equipped for such conditions and environments.
NOTE
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
The information in the chapter for handling the machine does not re-
lieve the operator of the responsibility of following laws or other nation-
al regulations for road safety and work safety.
Awareness, alertness, good judgement and respect for governing
safety regulations are prerequisites for avoiding accident risks.
Environmental impact
–
It is important that the machine is used in a way that results in minimal

environmental impact with regards to fuel consumption, exhausts, and
noise emissions. Therefore, keep the following in mind:
• Plan the work and optimise machine use.
• Avoid operating with full throttle when transporting.
• Do not rev the engine unnecessarily when load handling.
• Optimise operation with regard to acceleration and braking.
• Minimise the time that the machine idles. Do not allow the ma-
chine to idle when there is a break in the work.

84 5 Handling
Emergency equipment
–
The following emergency equipment is available on the machine:
• Emergency exit, right door and rear window ( ).

In an emergency:
1. Open the emergency exit right-hand door with handle on inside.
2. In case the doors are blocked by lift cylinders, open the emer-
gency exit rear window by removing the split pin and handle on re-
spective side of the rear window, see figure.
For a machine with hydraulic vertically adjustable cab, there is a
hammer for breaking the window instead of a window that can be
000382 opened.
Emergency exit rear window

• Control breaker
In an emergency:
1. Press down the control breaker (position 7) immediately.
All power transmission and control signals to hydraulics stop.
Reset control breaker (turn clockwise).
30-35
30-35
006770
9 7
7. Control breaker
9. Control lever

5 Handling 85
• Emergency lowering valve (Hydraulic vertically adjustable of

cab)
If the cab should get stuck in the raised position, it can be lowered
manually using an emergency lowering valve (position A). It’s lo-
cated at the front in the engine compartment (under the front cover
plate for the engine compartment).
1. Remove any lock lug.
2. Turn the emergency lowering valve. The cab is lowered.
A
• Fire extinguisher
Located within easy reach!
001978

86 5 Handling – 5.1 Running-in
5.1 Running-in
General
page
–
The machine should be operated with great care during the run-in pe-
riod. The purpose is to give bearing surfaces hard and polished sur-
faces, which considerably extends the service life.
Recommended run-in period is 10 hours of operating time. This gives
fewer malfunctions.
Engine
–
A new engine shall always be handled with great care – it must have
a run-in period. Avoid running the engine at full load during the first
10 hours. Then, loading of the engine can be increased gradually.
NOTE
Check the oil pressure and temperature at regular intervals.
Oil and filter should be changed for the first time after 50 operating
hours.
Thereafter oil and filter changes take place according to intervals de-
scribed in the maintenance manual.
For engine alternative Volvo TAD1250VE there may be deviations
from the service interval. Depends on the oil grade used in the engine
(contact service). Engine TAD1250VE should be run with oil specifica-
tion VDS-3. The engine can be run with oil specification VDS-2
(ACEA E5), however, this shortens the service interval to 400 hours.
Transmission
–
Filter shall be changed the first time at 50 operating hours. Then oil is
changed according to intervals described in the maintenance manual.
Tyres and rims

–
For a new machine it is extremely important that the wheel nuts are
check-tightened during the first work until they have ’set.’ This shall be
done at intervals of 4-5 operating hours (up to approx. 40-50 operating
hours). Then the wheel nuts are check-tightened according to intervals
described in the maintenance manual.

5 Handling – 5.2 Daily inspection 87
5.2 Daily inspection

General
page
–
Daily inspection of the machine is extremely important in order to en-

sure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
Never use a machine without first performing the dai-
ly inspection.
Risk of personal injury and property damage!
For work instruction, see section 6.1 Daily inspection.

Notify the foreman/supervisor immediately if defects
are found on the machine during daily inspection!
For work instructions, see section 6.1 Daily inspection.

88 5 Handling – 5.3 Error codes
5.3 Error codes

General
page
–
Error codes indicate there is some defect/malfunction in the machine.

The error codes should be used by operators and service technicians
to identify the problem and to perform a suitable action.
In case of an error code indication, it’s very important to identify the er-
ror code and to perform an action to correct the problem.
Error codes are shown automatically on the display and end up in an
error code list under the operating menu for service.
Action in the event of error code

–
CAUTION
STOP indicates a malfunction in the machine which
may affect safety of the operator and others in the vi-
cinity or may cause a breakdown. – Switch off the en-
gine and perform action according to error code table.
WARNING and INFORMATION indicate malfunctions

of such character that work does not have to be
stopped. The machine’s capacity may be limited and
certain functions may not work. – Perform actions ac-
cording to error code table as soon as possible.
1 Stop the machine and let the engine run at idle speed.
Identify error code level, see section 5.3.1 Error code indication.
• In case of STOP – Continue to step 4.
• In case of WARNING or INFORMATION – Continue to
step 2.
NOTE
If several error codes come from the engine, the error code
level is shown for the most serious error code.
2 Navigate to the operating menu for service using the function
keys arrow left or arrow right. Hold down the function key Enter
for at least two seconds. The error code list is shown.
000056
Operating menu for service

5 Handling – 5.3 Error codes 89
3 Note all error codes. For explanation, see Display figure for error
code information page 91.
Error code number together with X(Y). X shows sequence
number for displayed error code and (Y) shows total number of
active error codes. Scroll between the error codes with the func-
001998
tion keys arrow right and arrow left. The error code indication dis-
appears when the cause of an error code has been corrected.
Example figure, error code list
Leave the error code list by pressing the function key Reset (R).
4 Perform action according to error code level:
STOP, critical malfunction!
A. Park the machine immediately.
Note error code number.
B. Turn off engine.
C. Contact service.
WARNING, not a critical malfunction.
A. Take care of error code as soon as possible but work
with machine can continue safely.
B. See information in error code table:
- Error codes machine page 94
- Error codes engine page 104
- Error codes transmission page 118
If error code number is not in error code table, perform
action according to step C.
C. Contact service, e.g., after finished work shift.
INFORMATION, not a critical malfunction.
A. Continue work with machine.
B. At a suitable time, see information in error code table:
- Error codes machine page 94
- Error codes engine page 104
- Error codes transmission page 118
If error code number is not in error code table, perform
action according to step C.
C. Contact service, e.g., after finished work shift.
5 Check: Start the engine and check that the error code has disap-
peared acc. to step 2.

90 5 Handling – 5.3.1 Error code indication
5.3.1 Error code indication

General
page
–
Error code is indicated with an activated indicator light for active error
51 52
codes (position 34). The error codes are divided into three error code
levels depending on their severity.
The error code levels are shown as follows:
• Stop is indicated with a STOP sign on the display together with
flashing red light from the indicator for the control and monitoring
B system (position 52) as well as activated indicator light for active
error codes (position 34).
• WARNING is indicated with a warning triangle on the display to-
gether with flashing red light from the indicator for the control and
34 monitoring system (position 52) as well as activated indicator for
active error codes (position 34).
• Information is indicated with activated indicator light for active er-
ror codes (position 34).
005075
B. Symbol error code level

34 Indicator light for active error codes
51 Display for control and monitoring system
52 Indicator for control and monitoring system
5.3.2 Error code information on display

Error code display
page
–
Error code information is shown with display figures in two ways:

• Automatically in display at STOP and WARNING.
The error code is confirmed with function key Reset (R). When the
error code is confirmed, the display returns to the previous select-
ed menu. If the error code is active, it’s stored in the error code list
under operating menu for service.
002207
If the error code remains active, the figure returns in the display
within 3-5 minutes.
Example of automatic figure in display
• In the error code list under operating menu for service.
Active error codes are stored in the error code list. Navigate to the
operating menu for service. Display the error code list by pressing
in function key Enter for 2 seconds. Navigate in the error code list
with function keys arrow right and arrow left. Leave the error code
list by pressing function key for Reset (R).
001998
Example of display in the error code list NOTE

If error code isn’t included in the error code list, it may be due
to the following:
- condition for error detection no longer exists, e.g., control le-
ver is released or engine is off.
- loose connection/poor contact

5 Handling – 5.3.2 Error code information on display 91
Display figure for error code information

–
The control and monitoring system’s display is divided into four fields
C where the information is shown (see figure to the left).
D E • Field B: Error code level.

• Field C: Error code number.
B
000389
• Field D: Type of error.
• Field E: Affected function.
• Book symbol means that information is available in the operator’s
manual.
Field B: Error code level

The control and monitoring system gives error code information in
three levels which are indicated with a symbol in the lower left corner
(B) on the display unit.
• STOP
C Indicates a serious malfunction that may jeopardise the operator’s
safety or cause machine failure. Error code shall be taken care of
D E
immediately.
The error code is shown automatically on the display.
000350
• WARNING
C Indicates malfunction in machine that should be taken care of as
soon as possible.
D E
The error code is shown automatically on the display.
000351
• INFORMATION
C Information to operator about something that should be taken care
of, e.g., broken bulb. Take care of the cause at a suitable time. Ac-
D E tion instruction is often found in chapter 6 Inspection and
maintenance.
000352
The error code is stored in the error code list under operating
menu for service.

92 5 Handling – 5.3.2 Error code information on display
Field C: Error code number

The control and monitoring system gives error codes from three
sub-systems:
• Machine:
XXX
Shown with error code number XXX on display, see Error codes
D E machine page 94.
006499 • Engine:
XX/YY Shown with error code number XXX/YY on display, see Error
codes engine page 104.
D
B NOTE
001343
If several error codes come from the engine, the error code
level is shown for the most serious error code.
• Transmission:
XXX/YY Shown with error code number XX/YY on display, see Error codes
transmission page 118.
D
B
001344
Field D: Type of error

1. Temperature too high/too low.
1 2 3
2. Incorrect signal to solenoid valve.
3. Incorrect hydraulic pressure.
4. Incorrect sensor signal.
4 5 6 5. Incorrect signal from control.

6. Incorrect signal to bulb.
7. Incorrect signal, for example, open circuit.
7
000396

5 Handling – 5.3.2 Error code information on display 93
Field E: Affected function

1. Attachment
1 2 3
2. Rotation of attachment
3. Side shift, attachment
4. Extension (spreading) attachment
4 5 6
5. Levelling attachment
6. Twistlocks
7. Variable tilt, attachment
7 8 9 8. Bottom lift attachment
9. Bottom lift attachment, clamping position
10. Bottom lift attachment, legs up/down
10 11 12 11. Boom up/down

12. Boom in/out
13. Pressure sensor lift cylinder (overload system, OP)
14. Non-existent overload system
13 14 15
15. Support jacks up/down
16. Hydraulic functions
17. Brake system
16 17 18
18. Steering
19. Engine
20. Transmission
19 20 21 21. Central lubrication
22. Control unit
23. Hardware-related error
22 23 24 24. Cab
25. Air conditioning
26. Fuel system
25 26 27 27. Headlights
28. Windscreen wipers
29. Battery voltage
28 29 30 30. Bulb for lighting
000397

94 5 Handling – 5.3.3 Error code tables
5.3.3 Error code tables

General
page
–
Error codes are sorted in numerical order. The tables contain the fol-
lowing information:
• Code - Indicates error code.
• Description - Indicates description of the error code as well as any
limitation that can occur in the machine in case of the error code
in question.
• Action - Indicates STOP/WARNING/INFORMATION for action ac-
cording to error code level, with or without detailed information.
If the error code number isn’t included in the error code table, contact
service.
Error codes machine

–
Code Description Action

1 No contact with control unit attachment. Attachment functions not STOP
working.
2 No contact with control unit attachment option. Levelling and tilt not STOP
working.
3 No contact with control unit attachment left leg pair. Left side of bottom STOP
lift attachment not working.
4 No contact with control unit attachment right leg pair. Right side of bot- STOP
tom lift attachment not working.
5 No contact with control unit frame rear. Lights rear, hydraulic oil cooling, STOP
overload system, extension not working.
6 No contact with control unit frame front option. Sliding cab, support STOP
jacks, joystick, mini-wheel and cab lift not working.
7 No contact with control unit frame front. Front lights, lift, extension, STOP
brake lights, brake cooling not working.
8 No contact with control unit KID. Controls in steering wheel panel and STOP
display not working.
11 CAN segment 1. WARNING
20 Accelerator pedal has to be calibrated. Poor sensitivity in accelerator INFORMATION

pedal.

5 Handling – 5.3.3 Error code tables 95

21 No contact with control unit transmission. Gear selection not working. STOP
22 No contact with control unit engine. Engine does not respond to com- STOP
mands from cab.
23 Machine is not configured. No controls in cab are working. STOP
24 Incorrect voltage feed to cab fan. Cab fan not working. INFORMATION: Check fuse F58-5:C3.
See 6.2.14 Fuses for electrical system.
25 Communication error with control unit engine at active error code. INFORMATION: Turn ignition off and
Error code is stored in control unit engine. on.
26
27
28
29
30
31 Voltage feed incorrect to control unit cab. Controls in cab not working. STOP: Check fuse F58-4:A1. Se 6.2.14
Fuses for electrical system.
32 Analogue controls cab. Analogue controls in cab not working (mini- STOP
wheel/joystick, control lever and controls for air conditioning).
33 No feed of control breaker voltage to control unit cab. Control breaker WARNING: Check fuse F58-3:H8. See
cannot be disengaged. All hydraulic functions are blocked. 6.2.14 Fuses for electrical system.
34 Switch parking brake. Parking brake cannot be released. WARNING: Use by-pass to release the
parking brake.
35 Communication error with control unit transmission at active error code. INFORMATION: Turn ignition off and
Error code is stored in control unit transmission. on.
36
37
38
39
40
41 Wiper rear not working. INFORMATION
42 Revolving beacon not working. INFORMATION: Check the light. See

6.2.15 Lighting.
43 Work light left cab not working.
44 Work light right cab not working.
45 Wiper front not working. INFORMATION
46 Cab fan not working. INFORMATION
47 Recirculation damper for ventilation not working. INFORMATION
48 Water valve. Heat in cab cannot be adjusted. INFORMATION
49 Water valve. Heat in cab cannot be adjusted. INFORMATION
50 Air distribution in cab cannot be adjusted. INFORMATION


53 Windscreen washer rear and roof not working. INFORMATION
54 Bulb in switch flashing hazard lights not working. INFORMATION
55 Reduced or no background lighting in instruments and controls. INFORMATION: Check lights for back-
ground lighting. See 6.2.15 Lighting.
56 LED control lever for adjustable tilt. INFORMATION: Check light. See
6.2.15 Lighting.
57 LED control lever for locking tilt/levelling. INFORMATION: See 6.2.15 Lighting.
60 Seat heat not working. INFORMATION
61 Extra work lights boom not working. INFORMATION
62 No voltage feed to hour meter and air-suspended seat. INFORMATION
63 No ignition voltage to the machine’s control units. STOP
64 No control breaker voltage to the machine’s control units. STOP
65 No control breaker voltage to the machine’s control units. STOP
66 Washer front not working. INFORMATION
67 Wiper roof not working. INFORMATION
68 Pause heater not working. INFORMATION
69 No voltage feed to engine and transmission. STOP
71 Interior lighting in cab not working. INFORMATION: Check the light. See
6.2.15 Lighting.
74 Horn/loud horn not working. INFORMATION Horn in gear and multi-

function lever may be deactivated in
software.
75 Relay for ignition has jammed in position on. Control unit cab is still sup- STOP
plied with voltage and thus active.
80 Incorrect pressure in air conditioning. Air conditioning not working. INFORMATION
85 Accelerator pedal. Engine rpm limited to idle. STOP
87 Control lever for lift and lower. Lift and lower not working. WARNING
88 Control lever for extension. Extension not working. WARNING
89 Control lever for rotation. Rotation not working. WARNING
90 Control lever for tilt. Adjustable tilt not working. WARNING
92 Joystick or mini-wheel. Joystick or mini-wheel not working. WARNING
93 Mini-wheel. Mini-wheel not working. WARNING
94 Water valve cab heat. Cab heat cannot be adjusted. INFORMATION
96 Sensor cab temperature. Temperature control cab not working. INFORMATION


97 Sensor outdoor temperature. Temperature control cab not working. INFORMATION
98 Sensor temperature outlet fan. Temperature control cab not working. INFORMATION
99 Sensor temperature refrigerant. Temperature control cab not working. INFORMATION
101 Redundant voltage feed left control unit frame front. STOP: Turn ignition off and on.
102 Redundant voltage feed right control unit frame front. STOP: Turn ignition off and on.
103 Voltage feed control unit frame front. No power supply to components STOP: Check fuse F58-2:A1. See
from control unit frame front. 6.2.14 Fuses for electrical system.
104 Control breaker voltage to control unit frame front. Control breaker can- WARNING: Check fuse F58-3:B2. See
not be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
105 Voltage feed sensor. Regeneration lift, weight indicator and overload STOP
system not working.
106 Cooling fan brake system not working. WARNING
107 Left high beam not working. INFORMATION: Check the light. See
6.2.15 Lighting.
108 Right high beam not working. INFORMATION: Check the light. See
6.2.15 Lighting.
110 Low beam right and left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
111 Solenoid valve boom up. Lift not working. WARNING
112 Solenoid valve boom down. Lower not working. WARNING
113 Solenoid valve boom out. Extension out not working. WARNING
114 Solenoid valve boom in. Extension in not working. WARNING
115 Solenoid valve blocking lift left. Lift and lower not working. WARNING
116 Solenoid valve blocking lift right. Lift and lower not working. WARNING
117 Solenoid valve regeneration lift right. Regeneration lift not working. WARNING
118 Solenoid valve regeneration lift left. Regeneration lift not working. WARNING
119 Solenoid valve parking brake. Parking brake cannot be released. STOP
120 Direction indicator left front. Direction indicator front left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
121 Direction indicator right front. Direction indicator front right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
122 Running light left front. Running light front left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
123 Running light right front. Running light front right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
133 Sensor hydraulic pressure lift cylinder left. Overload system not work- STOP
ing. All lift functions run at reduced speed. Error code 150 activated.


134 Sensor hydraulic pressure lift cylinder left. Overload system not work- STOP
135 Sensor hydraulic pressure lift cylinder right. Overload system not work- STOP
136 Sensor hydraulic pressure lift cylinder right. Overload system not work- STOP
137 Solenoid valve boom down. Lower not working. WARNING
138 Solenoid valve boom up. Lift not working. WARNING
139 Solenoid valve boom out. Extension out not working. WARNING
140 Solenoid valve boom in. Extension in not working. WARNING
145 Sensor boom angle. Overload system not working. STOP
146 Sensor boom length. Overload system not working. STOP
147 High oil temperature in brake system. Reduced braking capacity. If tem- WARNING: Check that cooling fan
perature continues to increase, speed limitation will take place. works. Check that radiator is not
clogged. Check oil level in brake sys-
tem. See 6.2.8 Oil brake system.
148 Sensor oil temperature in brake system. Incorrect temperature display. WARNING
Immediate speed limitation.
149 Incorrect load curve or load curve missing. Lift and lower as well as ex- STOP
tension not working.
150 Overload system not working. All lift functions run at reduced speed. STOP: Retract the boom completely.
Gives indication at Reset of error codes for overload system. Indication Lower the load slowly. Unload contain-
of this error code cannot be removed with Reset. er. Contact service. NOTE! Overload
system is disengaged.
151 Voltage feed control unit frame rear. STOP: Turn ignition off and on.
152 Voltage feed control unit frame rear. STOP: Turn ignition off and on.
153 Voltage feed control unit frame rear. No power supply to components STOP: Check fuse F58-2:C3. See
from control unit frame rear. 6.2.14 Fuses for electrical system.
154 Voltage feed control unit frame rear. WARNING: Turn ignition off and on.
155 Voltage feed sensor. Overload system and weight indicator not STOP
working.
156 Cooling fan hydraulic oil. Cooling fan hydraulic oil not working. WARNING
157 Work light boom left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
158 Work light boom right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
159 Back-up light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.


160 Back-up light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
161 Voltage feed sensor overload system. Overload system indicates STOP
overload.
162 Voltage feed position sensor boom. Damping in/out/1.5m not working. INFORMATION
163 Solenoid valve regeneration extension. Regeneration extension not WARNING

working.
164 Solenoid valve blocking extension. Extension not working. WARNING
165 Back-up alarm not working. INFORMATION
166 Solenoid valve top hydraulics. Attachment functions not working. WARNING
167 Brake light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
168 Brake light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
169 Running light left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
170 Running light right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
171 Tail light left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
172 Tail light right not working. INFORMATION: Check the light. See
6.2.15 Lighting.
173 Direction indicator left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
174 Direction indicator right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
175 Sensor steering axle. Overload system indicates overload. STOP
178 Solenoid valve unloading pump. Unloading of hydraulic oil pumps at WARNING
boom not working.
183 Sensor boom angle. Overload system not working. STOP
184 Sensor boom length. Overload system not working. STOP
191 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
192 Magnetic clutch AC compressor. Air conditioning not working. INFORMATION
193 Start relay starter motor. Starter motor not working. WARNING
197 High temperature hydraulic oil. WARNING: Check that cooling fan
works. Check that radiator is not
clogged. Check oil level in hydraulic
system. See 6.2.9 Hydraulic system.
198 Sensor hydraulic oil temperature. Incorrect temperature display. WARNING


199 Sensor fuel level. Incorrect display of fuel volume (empty or full). INFORMATION: Check fuel volume
manually in tank. See 6.2.2 Fuel sys-
tem.
201 Voltage feed control unit frame option. STOP: Turn ignition off and on.
202 Voltage feed control unit frame option. STOP: Turn ignition off and on.
203 Voltage feed control unit frame option. No power supply to components STOP: Check fuse F58-2:D4. See
from control unit frame option. 6.2.14 Fuses for electrical system.
204 Voltage feed control unit frame option. Control breaker for hydraulics STOP: Check fuse F58-3:D4. See
cannot be disengaged. All hydraulic functions blocked. 6.2.14 Fuses for electrical system.
211 Solenoid valve cab front/up. Hydraulic sliding cab or cab lift not working. WARNING
212 Solenoid valve cab rear/down. Hydraulic sliding cab or cab lift not WARNING
working.
213 Solenoid valve steering left. Joystick or mini-wheel not working. WARNING
214 Solenoid valve steering right. Joystick or mini-wheel not working. WARNING
215 Solenoid valve support jack up. Support jacks not working. WARNING
216 Solenoid valve support jack down. Support jacks not working. WARNING
217 Solenoid valve cab tilt up. Cab tilt not working. WARNING
218 Solenoid valve cab tilt down. Cab tilt not working. WARNING
219 Solenoid valve disengagement of hydraulic oil pumps. WARNING
220 Voltage feed position sensor support jacks. If indication support jacks INFORMATION
up is missing, gear cannot be selected to operate machine.
221 Voltage feed cab lift. Cannot be indicated that cab is in lowered position. INFORMATION
Door must be closed so that boom can be lowered. Speed limitation
activated.
237 Solenoid valve cab front/up. Hydraulic sliding cab or cab lift not working. WARNING
238 Solenoid valve cab rear/down. Hydraulic sliding cab or cab lift not WARNING
working.
239 Solenoid valve steering left. Joystick or mini-wheel not working. WARNING
240 Solenoid valve steering right. Joystick or mini-wheel not working. WARNING
251 Voltage feed control unit attachment. STOP: Turn ignition off and on.
253 Voltage feed control unit attachment. STOP: Check fuse F58-3:A1. Se 6.2.14
Fuses for electrical system.
254 Voltage feed control unit attachment. No attachment functions working. INFORMATION: Check fuse F58-3:A1.
See 6.2.14 Fuses for electrical system.
257 Work light attachment right not working. INFORMATION: Check the light. See
6.2.15 Lighting.


258 Work light attachment left not working. INFORMATION: Check the light. See
6.2.15 Lighting.
259 Buzzer automatic spreading 20’ to 40’. INFORMATION: Check the light. See
6.2.15 Lighting.
260 Extra work light attachment not working. INFORMATION: Check the light. See
6.2.15 Lighting.
261 Solenoid valve rotation clockwise. Rotation of attachment not working. WARNING
262 Solenoid valve rotation counter-clockwise. Rotation of attachment not WARNING

working.
263 Solenoid valve spreading out. Spreading not working. WARNING
264 Solenoid valve spreading in. Spreading not working. WARNING
265 Solenoid valve side shift right. Side shift of attachment not working. WARNING
266 Solenoid valve side shift left. Side shift of attachment not working. WARNING
267 Solenoid valve lock twistlocks. Twistlocks not working. WARNING
268 Solenoid valve open twistlocks. Twistlocks not working. WARNING
269 Solenoid valve tilt lock 1. Tilt lock not working. WARNING
270 Solenoid valve tilt lock 2. Tilt lock not working. WARNING
271 Voltage feed position sensor attachment. WARNING
272 Indicator light twistlocks open not working. WARNING: Check the light. See 6.2.15
Lighting.
273 Indicator light alignment not working. WARNING: Check the light. See 6.2.15
Lighting.
274 Indicator light twistlocks locked not working. WARNING: Check the light. See 6.2.15
Lighting.
287 Solenoid valve rotation clockwise. Rotation of attachment not working. WARNING
288 Solenoid valve rotation counter-clockwise. Rotation of attachment not WARNING

working.
289 Solenoid valve spreading out. Spreading not working. WARNING
290 Solenoid valve spreading in. Spreading not working. WARNING
298 Twistlock left in middle position. Lift and extension not working. WARNING: Check that left twistlock
sensors are clean and free from grease.
299 Twistlock right in middle position. Lift and extension not working. WARNING: Check that right twistlock
sensors are clean and free from grease.
300 Sensor alignment. Twistlocks not working. WARNING: Check that the alignment
sensors are clean and free of grease.
Check that the alignment pins are not
stuck in alignment position.


303 Voltage feed control unit attachment. Control breaker for hydraulics STOP: Check fuse F58-3:A1. Se 6.2.14
cannot be disengaged. All hydraulic functions blocked. Fuses for electrical system.
311 Solenoid valve levelling right. Levelling not working. WARNING
312 Solenoid valve levelling left. Levelling not working. WARNING
313 Solenoid valve tilt out. Adjustable tilt not working. WARNING
314 Solenoid valve tilt in. Adjustable tilt not working. WARNING
315 Solenoid valve levelling 1. Levelling not working. WARNING
316 Solenoid valve levelling 2. Levelling not working. WARNING
317 Incorrect output signal auxiliary attachment. WARNING
354 Voltage feed control unit attachment. Control breaker for hydraulics WARNING: Check fuse F58-3:A1. See
357 Work light left lift leg not working. INFORMATION: Check the light. See
6.2.15 Lighting.
358 Solenoid valve levelling. Levelling not working. WARNING
360 Solenoid valve operating position left. Left lift leg not working. WARNING


363 Solenoid valve front knee left in. Left lift leg not working. WARNING
364 Solenoid valve front knee left out. Left lift leg not working. WARNING
365 Solenoid valve rear knee left in. Left lift leg not working. WARNING
366 Solenoid valve rear knee left out. Left lift leg not working. WARNING
367 Solenoid valve front leg left down. Left lift leg not working. WARNING
368 Solenoid valve front leg left up. Left lift leg not working. WARNING
369 Solenoid valve rear leg left down. Left lift leg not working. WARNING
370 Solenoid valve rear leg left up. Left lift leg not working. WARNING
371 Indicator light alignment lift leg right front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
372 Indicator light alignment lift leg right rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
373 Indicator light alignment lift leg left front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
374 Indicator light alignment lift leg left rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
375 Solenoid valve clamp left shut. Left lift leg not working. WARNING
376 Solenoid valve clamp left open. Left lift leg not working. WARNING
377 Voltage feed position sensor left leg pair. WARNING
404 Voltage feed control unit attachment. Control breaker for hydraulics WARNING: Check fuse F58-3:A1. See
407 Work light right lift leg not working. INFORMATION: Check the light. See
6.2.15 Lighting.
410 Solenoid valve operating position right. Right lift leg not working. WARNING
413 Solenoid valve front knee right in. Right lift leg not working. WARNING


414 Solenoid valve front knee right out. Right lift leg not working. WARNING
415 Solenoid valve rear knee right in. Right lift leg not working. WARNING
416 Solenoid valve front knee right out. Right lift leg not working. WARNING
417 Solenoid valve front leg right down. Right lift leg not working. WARNING
418 Solenoid valve front leg right up. Right lift leg not working. WARNING
419 Solenoid valve rear leg right down. Right lift leg not working. WARNING
420 Solenoid valve rear leg right up. Right lift leg not working. WARNING
421 Indicator light front legs raised not working. INFORMATION: Check the light. See
6.2.15 Lighting.
422 Indicator light front legs lowered not working. INFORMATION: Check the light. See
6.2.15 Lighting.
423 Indicator light clamping position lift leg front not working. INFORMATION: Check the light. See
6.2.15 Lighting.
424 Indicator light clamping position lift leg rear not working. INFORMATION: Check the light. See
6.2.15 Lighting.
425 Solenoid valve clamp right shut. Right lift leg not working. WARNING
426 Solenoid valve clamp right open. Right lift leg not working. WARNING
427 Voltage feed position sensor right leg pair. WARNING
451 Voltage feed control unit display. WARNING: Turn ignition off and on.
452 Voltage feed control unit display. WARNING: Turn ignition off and on.
460 Communication error with control unit KID (D795). Incorrect values in STOP
operating menus.
461 Communication error with control unit KID (D795). Error codes from oth- STOP
er control units cannot be shown.
500 Time for service. INFORMATION: Bring machine to

service.
Error codes engine

–
For contact with engine suppliers, use Volvo/Cummins code.

• Display indicates error code acc. to SAE J1939
SPN / FMI
• Flash indicates error code according to engine supplier specified
flash code.
• J1587 indicates error code acc. to SAE J1587 (for Volvo: Vodia).
PID, PPID, SID, PSID / FMI

Table 1. Specifications FMI
FMI Description SAE-text

0 Too high value. Data valid, but higher than normal operating range.
1 Too low value. Data valid, but lower than normal operating range.
2 Incorrect data. Intermittent or incorrect data.
3 Electrical problem. Abnormally high voltage or short-circuit to higher voltage.
4 Electrical problem. Abnormally low voltage or short-circuit to lower voltage.
5 Electrical problem. Abnormally low current or open circuit.
6 Electrical problem. Abnormally high current or short-circuit to ground.
7 Mechanical problem. Incorrect response from mechanical system.
8 Mechanical problem or electrical Abnormal frequency.

problem.
9 Communication error. Abnormal update rate.
10 Mechanical problem or electrical Abnormally wide variations.

problem.
11 Unknown malfunction. Non-identifiable malfunction.
12 Component error. Incorrect unit or component.
13 Incorrect calibration. Values outside calibration values.
14 Unknown malfunction. Special instructions.
15 Unknown malfunction. Reserved for future use.
16 Too high value. Data valid, but higher than normal operating range. Moderately
serious level
17 Too low value. Data valid, but lower than normal operating range. The least serious
level
18 Too low value. Data valid, but lower than normal operating range. Moderately
serious level
19 Communication error. Received network data incorrect
20-30 Reserved for SAE-allocation
31 FMI not available or the condition indicat- Not available or the condition exists
ed by SPN exists.

Table 2. Error codes Volvo TAD1250VE and TAD1240VE
Description Action
Display J1587
94/1 PID94/1 Sensor fuel pressure, low fuel pressure. STOP
94/3 PID94/3 Sensor fuel pressure, cable short-circuited to voltage. STOP
94/5 PID94/5 Sensor fuel pressure, cable open circuit or short-circuited to STOP
ground.
97/0 PID97/0 Water in fuel. WARNING: Drain fuel pre-filter,

see 6.2.2 Fuel system.
97/3 PID97/4 Sensor water in fuel, cable short-circuited to voltage. STOP
98/1 PID98/1 Low engine oil level. STOP: Check oil level in engine.
See 6.2.6 Engine oil.
98/5 PID98/5 Sensor engine oil level, cable open circuit or short-circuited STOP: Check oil level in engine.
to ground. See 6.2.6 Engine oil.
100/1 PID100/1 Low engine oil pressure. Reduced engine power. STOP: Check oil level in engine.
See 6.2.6 Engine oil.
100/3 PID100/3 Sensor oil pressure cable short-circuited to voltage. STOP
100/5 PID100/5 Sensor oil pressure, cable open circuit or short-circuited to STOP
ground.
105/0 PID105/0 Too high charge-air temperature. Reduced engine power. STOP
105/4 PID105/4 Sensor charge-air temperature, cable short-circuited to STOP

ground.
105/5 PID105/5 Sensor charge-air temperature, cable open circuit. STOP
106/0 PID102/0 High boost pressure. Reduced engine power. STOP
106/3 PID102/3 Sensor boost pressure, cable short-circuited to voltage. En- STOP
gine smokes more than normal at acceleration/load.
106/5 PID102/5 Sensor boost pressure, cable open circuit. Engine smokes STOP
more than normal when accelerating/under load.
107/1 PID107/1 Low air pressure. STOP
107/3 PID107/3 Sensor, air pressure, cable short-circuited to voltage. STOP
107/5 PID107/5 Sensor air pressure, cable open circuit. STOP
110/0 PID110/0 High coolant temperature. Reduced engine power or engine STOP: Check coolant level. See
is turned off. 6.2.5 Cooling system.
110/4 PID110/4 Sensor coolant temperature, cable short-circuited to frame. STOP

Preheating activated even when engine is warm. Engine dif-
ficult to start.

Description Action
Display J1587
110/5 PID110/5 Sensor coolant temperature, cable open circuit. Preheating STOP
activated even when engine is warm. Engine difficult to start.
111/1 PID111/1 Low coolant level. Reduced engine power. STOP: Check coolant level. See
6.2.5 Cooling system.
111/3 PID111/3 Sensor coolant level, cable short-circuited to voltage STOP
158/1 PID158/1 Low battery voltage. Engine may be difficult to start. STOP
172/4 PID172/4 Sensor air temperature, cable short-circuited to ground. STOP
172/5 PID172/5 Sensor air temperature, cable open circuit. STOP
175/0 PID175/0 High engine oil temperature. Reduced engine power. STOP
175/4 PID175/4 Sensor, oil temperature, cable short-circuited to frame STOP

ground.
175/5 PID175/5 Sensor oil temperature, cable open circuit. STOP
190/0 PID190/0 Engine rpm too high. STOP
608/9 PPID98/9 Start/stop, redundance, abnormal update rate. STOP
608/3 PPID132/ Signal from accelerator pedal, redundance, cable short- STOP
3 circuited to voltage. Engine goes to idle.
608/4 PPID132/ Signal from accelerator pedal, redundance, cable short- STOP
4 circuited to ground. Engine goes to idle.
608/9 PPID132/ Signal from accelerator pedal, redundance, abnormal update STOP
9 rate. Engine goes to idle.
608/12 SID250/9 Defective data link. STOP
626/3 PID45/3 Preheating relay, cable short-circuited to voltage. Preheating STOP

cannot be activated. Engine difficult to start in cold weather.
626/4 PID45/4 Preheating relay, cable short-circuited to frame. Preheating STOP

constantly activated, fuse for preheating coil will blow.
626/5 PID45/5 Preheating relay, cable open circuit. Preheating cannot be STOP
activated. Engine difficult to start in cold weather.
629/3 SID254/3 Internal error engine control unit. STOP

Engine off: engine cannot be started. Engine running: engine
misfires.

Engine off: engine cannot be started. Engine running: engine
misfires.

Description Action
Display J1587
629/12 SID254/ Internal error engine control unit. STOP
12 Engine off: engine cannot be started. Engine running: engine
misfires.
630/all SID253/all Electrical problem. Engine cannot be started. STOP

FMI FMI
636/2 SID21/2 Sensor rpm camshaft. Irregular signal. Engine takes longer STOP
to start than normal. Engine runs normally once it has
started.
636/3 SID21/3 Sensor rpm camshaft. No signal. Engine takes longer to start STOP
than normal. Engine runs normally once it has started.
636/8 SID21/8 Sensor rpm camshaft. Abnormal frequency. Engine takes STOP
longer to start than normal. Engine runs normally once it has
started.
637/2 SID22/2 Sensor rpm flywheel. Irregular signal. Engine is extremely STOP
difficult to start and runs rough or stops.
637/3 SID22/3 Sensor rpm flywheel. Abnormal frequency. Engine is ex- STOP
tremely difficult to start and runs rough or stops.
637/8 SID22/8 Sensor rpm flywheel. Abnormal frequency. Engine is ex- STOP
tremely difficult to start and runs rough or stops.

Engine off: engine cannot be started. Engine on: engine goes
to idle mode and can only be stopped by using emergency
stop.
639/2 SID240/2 Memory error control unit engine. STOP

May not be possible to start engine.
639/7 SID240/7 Memory error control unit engine. STOP

May not be possible to start engine.
639/11 SID240/ Memory error control unit engine. STOP

11 May not be possible to start engine.
639/14 SID240/ Memory error control unit engine. STOP

14 May not be possible to start engine.
651/2 SID1/2 Electrical problem, injector cylinder 1, short-circuiting to volt- STOP

age. Engine only runs on 5 cylinders and has reduced power.


Description Action
Display J1587
651/4 SID1/4 Electrical problem, injector cylinder 1, short-circuiting to STOP
ground. Engine only runs on 5 cylinders and has reduced
power.
651/5 SID1/5 Electrical problem, injector cylinder 1, cable open circuit. En- STOP
gine only runs on 5 cylinders and has reduced power.
651/7 SID1/7 Compression malfunction or defective injector cylinder 1. STOP

Rough running at low rpm and low load.
651/9 SID1/9 Electrical problem, injector cylinder 1, open circuit. Engine STOP
only runs on 5 cylinders and has reduced power.
651/12 SID1/12 Electrical problem, injector cylinder 1, low current. Engine STOP



power.




power.


Description Action
Display J1587



power.




power.



Description Action
Display J1587

power.

677/3 PPID3/3 Start relay on starter motor, cable short-circuited to voltage STOP
or activated too long. Starter motor does not run.
677/4 PPID3/4 Start relay on starter motor, cable short-circuited to ground. STOP
Engine starts immediately when ignition is activated.
677/5 PPID3/5 Starter motor relay, open circuit on cable or defective compo- STOP
nent. Starter motor does not run.
1079/3 SID 232/3 Voltage feed sensor engine, cable short-circuited to voltage. STOP
1079/4 SID 232/4 Voltage feed sensor engine, cable short-circuited to frame. STOP
2047 / xx Undetectable error code from engine. Error codes over 2047 STOP
cannot be shown on display.
Possible error codes: 2791, 520192, 520194, 520195.
2791/3 PPID19/3 EGR status, cable short-circuited to voltage. STOP
2791/4 PPID19/4 EGR status, cable short-circuited to frame. STOP
2791/5 PPID19/5 EGR status, cable open circuit. STOP
2791/7 PPID19/7 EGR status. STOP
520192/1 PPID8 Sensor piston cooling pressure, short-circuiting to voltage, STOP

ground, or open circuit.
520192/3 PPID8 Low piston cooling pressure. STOP
520194/3 PPID4/3 Starter motor (start request), cable shorted to voltage or ac- STOP
tivated too long. Engine starts immediately when ignition is
activated.
520194/4 PPID4/4 Starter motor (start request), cable shorted to ground. Engine STOP
does not start.

Description Action
Display J1587
520195/4 PPID6/4 Ignition off (stop request), cable shorted to ground. STOP
Table 3. Error codes Cummins QSM11
Description Action
Display Flash J1587

84/2 241 PID084/2 Sensor speed, data invalid. Engine rpm limited WARNING
to max. rpm without gear.
84/10 242 PID084/ Sensor speed, incorrect signal. Engine rpm WARNING
10 limited to max. rpm without gear.
91/3 131 PID091/3 Accelerator pedal, cable short-circuited to volt- STOP

age. Engine does not respond to throttle.
91/4 132 PID091/4 Accelerator pedal, cable short-circuited to STOP

ground. Engine does not respond to throttle.
91/8 147 PID091/8 Accelerator pedal, too low frequency. Engine STOP
does not respond to throttle.
91/8 148 PID091/8 Accelerator pedal, too high frequency. Engine STOP
does not respond to throttle.
91/19 287 SID091/2 Problem with accelerator pedal. Engine only STOP
runs on idle.
97/3 428 PID097/3 Sensor water in fuel, cable short-circuited to WARNING

voltage.
97/4 429 PID097/4 Sensor water in fuel, cable short-circuited to WARNING

ground.
97/15 418 PID097/ Water in fuel. Risk of reduced engine power. WARNING: Drain fuel prefilter,
15 see 6.2.2 Fuel system.
100/1 415 PID100/1 Low engine oil pressure. Engine power is re- STOP: Check oil level in engine.
duced gradually, after 30 seconds the engine See 6.2.6 Engine oil.
is switched off.
100/2 435 PID100/2 Sensor oil pressure, data error. No warning in WARNING
case of low oil pressure.
100/3 135 PID100/3 Sensor oil pressure, cable short-circuited to WARNING

voltage. No warning in case of low oil pressure.

Description Action
Display Flash J1587

100/4 141 PID100/4 Sensor oil pressure, cable short-circuited to WARNING
ground or open circuit. No warning in case of
low oil pressure.
100/18 143 PID100/1 Low engine oil pressure. WARNING: Check oil level in en-
gine. See 6.2.6 Engine oil.
102/2 433 PID102/2 Sensor boost pressure indicates high boost WARNING
pressure when other engine data indicate that
pressure should be low. Reduced engine
power.
102/3 122 PID102/3 Sensor boost pressure, cable short-circuited to WARNING

voltage. Reduced engine power.
102/4 123 PID102/4 Sensor boost pressure, cable short-circuited to WARNING

ground or open circuit. Reduced engine power.
103/16 595 PID103/0 Incorrect overspeed protection for turbocharg- WARNING

ing. Reduced engine power.
105/0 155 PID105/0 Inlet air too warm. Engine power is reduced STOP
gradually, after 30 seconds the engine is
switched off.
105/3 153 PID105/3 Sensor charge-air temperature, cable short- WARNING

circuited to voltage or open circuit. No warning
at high coolant temperature.
105/4 154 PID105/4 Sensor charge-air temperature, cable short- WARNING

circuited to ground or open circuit. No warning
108/2 295 PID108/2 Sensor air pressure, data error. Reduced en- WARNING
gine power.
108/3 221 PID108/3 Sensor air pressure, cable short-circuited to WARNING

voltage. Reduced engine power.
108/4 222 PID108/4 Sensor air pressure, cable short-circuited to WARNING

ground. Reduced engine power.
110/0 151 PID110/0 High coolant temperature. Engine power is re- STOP: Check coolant level. See
duced gradually, after 30 seconds the engine 6.2.5 Cooling system.
is switched off.
110/3 144 PID110/3 Sensor coolant temperature, cable short- WARNING

circuited to voltage or open circuit. No warning
110/4 145 PID110/4 Sensor coolant temperature, cable short- WARNING

circuited to ground. No warning at high coolant
temperature.

Description Action
Display Flash J1587

111/1 235 PID111/1 Low coolant level. Engine power is reduced STOP: Check coolant level in en-
gradually, after 30 seconds the engine is gine. See 6.2.5 Cooling system.
switched off.
111/2 422 PID111/2 Sensor coolant level, data error. No warning at WARNING: Check coolant level
low coolant level. in engine. See 6.2.5 Cooling
system.
166/2 951 PID166/2 Power difference between cylinders. Rough INFORMATION

idling.
167/1 598 PID167/1 Low battery voltage. STOP
167/16 596 PID167/0 High battery voltage. WARNING
167/18 597 PID167/1 Low battery voltage or restart of engine repeat- WARNING
edly due to low battery voltage.
168/16 442 PID168/0 Voltage feed to control unit engine too high. WARNING
168/18 441 PID168/1 Voltage feed to control unit engine too low. WARNING
175/0 214 PID175/0 High engine oil temperature. Engine power is STOP
reduced gradually, after 30 seconds the en-
gine is switched off.
175/3 212 PID175/3 Sensor oil temperature, cable short-circuited to WARNING

voltage or open circuit. No warning at high oil
temperature engine.
175/4 213 PID175/4 Sensor oil temperature, cable short-circuited to WARNING

ground. No warning at high oil temperature
engine.
188/4 466 SID032/4 Solenoid valve 1 wastegate. Reduced engine WARNING

power.
190/0 234 PID190/0 High engine rpm. Fuel supply restricted until STOP: Use less throttle.
engine rpm is below permitted engine rpm.
190/10 121 PID190/ Sensor, speed/ignition position, one of two sig- WARNING
10 nals missing.
190/2 115 PID190/2 Sensor rpm/ignition position, both signals STOP

missing. Engine stops and cannot be started.
191/16 349 PID191/0 Incorrect calibration value. Speed limitation WARNING: Reduce throttle.
activated.
191/18 489 PID191/1 Speed warning for low speed. WARNING: Increase throttle.
251/2 319 PID251/2 Internal error engine control unit. INFORMATION

Description Action
Display Flash J1587

441/3 293 PID441/3 Extra sensor temperature, cable short- WARNING
circuited to voltage. No warning at high tem-
perature control unit.
441/4 294 PID441/4 Extra sensor temperature, cable short- WARNING

circuited to ground. No warning at high
temperature.
558/13 432 SID230/ Sensor accelerator pedal idle switch, calibra- STOP
13 tion error. Engine only runs at idle.
558/2 431 SID230/2 Sensor accelerator pedal idle switch, data WARNING
error.
558/4 551 SID230/4 Sensor accelerator pedal idle switch, cable WARNING
short-circuited to ground. Engine does not re-
spond to throttle.
608/2 412 SID250/2 Communication error Control unit engine. INFORMATION
626/11 381 SID237/ Control relay preheating. Preheating not WARNING

11 working.
627/2 434 SID251/2 Voltage feed to control unit engine disappears WARNING
without ignition off. Reduced engine power.
Difficult to start or engine stops.
629/12 111 SID254/ Internal error control unit engine. Engine does STOP
12 not start.
629/12 343 SID254/ Internal error engine control unit. WARNING

12
630/2 341 SID253/2 Internal error control unit engine. Reduced en- WARNING
gine power. Difficult to start or engine stops.
632/3 255 SID017/3 Solenoid valve fuel shut-off, cable short- WARNING
circuited to voltage.
632/4 254 SID017/4 Solenoid valve fuel shut-off, cable short- STOP
circuited to ground. Engine shuts down.
639/9 285 SID231/9 Communication error Control unit engine. WARNING
639/13 286 SID231/ Communication error Control unit engine. WARNING

13
644/2 237 SID030/2 Accelerator pedal, sensor outside valid range. WARNING
Engine shuts down.

Description Action
Display Flash J1587

647/4 245 SID033/4 Fan clutch, cable short-circuited to ground. WARNING
Cooling fan constantly activated.
651/5 322 SID001/5 Electrical problem, injector cylinder 1. Engine WARNING

only runs on 5 cylinders, has reduced power.











702/3 527 SID040 Extra input/output 2, cable short-circuited to WARNING

PID154/3 voltage.
703/3 529 SID051/3 Extra input/output 2, cable short-circuited to WARNING

voltage.
974/3 133 PID029/3 Extra accelerator pedal, cable short-circuited STOP

to voltage. Engine does not respond to throttle.
974/4 134 PID029/4 Extra accelerator pedal, cable short-circuited STOP

to ground. Engine does not respond to throttle.
974/19 288 PID029/2 Problem with accelerator pedal. Engine does STOP
not respond to throttle.

Description Action
Display Flash J1587

1043/3 387 PID221/3 Accelerator pedal reference voltage, short- WARNING
circuited to voltage. Engine runs at idle.
1043/4 443 SID221/4 Accelerator pedal reference voltage, short- WARNING

circuited to ground. Engine runs at idle.
1072/11 388 SID070/ Signal engine brake 1, short-circuited to WARNING

11 ground.
1073/11 392 SID029/ Signal engine brake 2, short-circuited to WARNING

11 ground.
1079/3 386 SID232/3 Reference voltage, short-circuited to voltage. WARNING

Reduced engine power.
1079/4 352 SID232/4 Reference voltage, short-circuited to ground. WARNING

Reduced engine power.
1080/3 227 SID232/3 Reference voltage to sensor short-circuited to WARNING

voltage. Reduced engine power. No warning at
low oil pressure or low coolant level.
1080/4 187 SID232/4 Reference voltage to sensor short-circuited to WARNING

ground. Reduced engine power. No warning at
low oil pressure or low coolant level.

power.

power.

power.
1265/4 223 SID085/4 Solenoid valve oil-burn, cable short-circuited to WARNING

ground.
1319/2 419 PID102/2 Incorrect value sensor boost pressure. Re- WARNING
duced engine power.
1377/2 497 SID114/2 Error in control unit transmission. WARNING
1380/17 219 PID017/1 Low oil level engine. INFORMATION: Check oil level
in engine. See 6.2.6 Engine oil.
1383/31 611 SID151/ Engine overheated. INFORMATION: Switch off en-

11 gine with ignition key lock.
1384/31 299 SID029/ Engine shutdown. WARNING: Switch off engine

14 with ignition key lock.
1387/3 297 PID223/3 Extra sensor pressure, cable short-circuited to WARNING

voltage. No warning for oil pressure.

Description Action
Display Flash J1587

1387/4 298 PID223/4 Extra sensor pressure, cable short-circuited to WARNING
ground. No warning for oil pressure.
1484/31 211 SID216/ Error codes in other control units. INFORMATION

11
Error codes transmission

–
Table 4. Error codes Dana TE32
Description Action
Code SPN/FMI
00/50 7F09D/C Memory error in control unit transmission. Transmission in STOP
locked neutral position (Shut-down).



20/60 7F065/1 Sensor gear 1/3. Transmission in locked neutral position STOP
(Shut-down).
20/61 7F065/0 Sensor gear 1/3. Transmission in locked neutral position STOP
(Shut-down).
21/00 7F069/1 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
21/01 7F069/0 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
22/00 7F06A/1 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
22/01 7F06A/0 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
23/00 7F06B/1 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
23/01 7F06B/0 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).

Description Action
Code SPN/FMI
24/00 7F06C/1 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
24/01 7F06C/0 Sensor oil pressure. Transmission in locked neutral posi- STOP
tion (Shut-down).
30/04 7F090/1 Low battery voltage. STOP
30/05 7F090/0 High battery voltage. WARNING
31/00 7F093/1 Reference voltage to sensor is too low. WARNING
31/01 7F093/0 Reference voltage to sensor is too high. WARNING
34/00 7F0BB/1F Sensor rotation speed wrong. Transmission locked to gear STOP
1 and 2 (Limp-home).
34/01 7F0BC/1 Measured turbine rpm at start is too low. Transmission STOP
locked to gear 1 and 2 (Limp-home).
34/02 7F0BD/0 Measured turbine rpm at start is too high. Transmission STOP
locked to gear 1 and 2 (Limp-home).
34/03 7F0BE/1 Incorrect oil pressure. Transmission locked in neutral posi- STOP
tion (Shut-down).
34/04 7F0BE/0 Incorrect oil pressure. Transmission locked in neutral posi- STOP
tion (Shut-down).
40/06 7F05E/2 Incorrect direction from gear selector. Transmission in WARNING

neutral.
40/08 7F041/1F Seat direction changed during operation. Transmission INFORMATION: Check seat direc-
locked in neutral position (Shut-down). tion or show the driver how the seat is
turned as per the correct procedure.
41/06 7F05F/2 Incorrect gear selection from gear selector. Control unit WARNING
does not allow change of gear range, however, operation of
machine is possible.
42/04 7F080/1 Actual gear ratio too low. One or several clutches slipping. STOP or WARNING
42/05 7F080/0 Actual gear ratio too high. One or several clutches slipping. STOP or WARNING
43/03 7F063/0 Sensor temperature torque converter WARNING
43/07 7F063/10 Torque converter’s temperature exceeds 100 C. WARNING: Note the error and try to
reduce temperature in torque con-
verter by operating calmly.

Description Action
Code SPN/FMI
43/08 7F063/0 Torque converter’s temperature exceeds 120 C. WARNING: Stop the machine, en-
The control unit protects the transmission and does not al- gage neutral and apply full throttle
low the temperature in the torque converter to exceeds the (limited to 50%) to cool the transmis-
limit value. Transmission in locked neutral position (Shut- sion oil so that temperature drops be-
down). Engine is limited to 50% of maximum rpm. low 100 C (error code 43/03
disappears).
When temperature in torque convert-
er is below 100 C, resume work with
machine.
44/10 7F0C6/9 Position accelerator pedal, message from engine’s control WARNING
unit.
45/06 7F048/2 Invalid combination for redundant digital speed inputs. INFORMATION
Speed limited.
46/05 7F036/F Max. torque at inching has been exceeded. WARNING: Stop the machine, select
neutral. Select gear again.
47/01 7F07B/10 Transmission has exceeded the limit value for upper rpm. INFORMATION: Release the accel-
erator pedal and slow down the
machine.
48/00 7F0B3/0 Disengaged 4WD/2WD-selector has jammed in engaged INFORMATION

position or the feedback signal is wrong.
48/01 7F0B3/1 Engaged 4WD/2WD-selector has jammed in engaged po- INFORMATION

sition or the return signal is wrong.
49/00 7F0B4/0 Disengaged Low/High-selector has jammed in engaged INFORMATION

position or the feedback signal is wrong.
49/01 7F0B4/1 Engaged Low/High-selector has jammed in engaged posi- INFORMATION

tion or the return signal is wrong.
50/00 7F010/4 Sensor gear 1/3. Transmission locked to gear 1 and 2 STOP
(Limp-home).
50/01 7F010/3 Sensor gear 1/3. Transmission locked to gear 1 and 2 STOP
(Limp-home).
50/04 7F010/11 Sensor gear 1/3, value error. INFORMATION
50/05 7F010/F Sensor gear 1/3, value error. INFORMATION
51/00 7F011/4 Sensor transmission oil temperature. WARNING
51/01 7F011/3 Sensor transmission oil temperature. WARNING
51/04 7F011/11 Sensor transmission oil temperature, value error. INFORMATION
51/05 7F011/F Sensor transmission oil temperature, value error. INFORMATION

Description Action
Code SPN/FMI
52/00 7F012/4 Temperature monitor torque converter short-circuited to INFORMATION
ground.
52/01 7F012/3 Temperature monitor torque converter. INFORMATION
52/04 7F012/11 Temperature monitor torque converter, value error. INFORMATION
52/05 7F012/F Temperature monitor torque converter, value error. INFORMATION
53/00 7F013/4 Analogue input signal, short-circuited to ground. Transmis- INFORMATION

sion locked to 1st and 2nd gear (Limp-home).
53/01 7F013/3 Analogue input signal, is not connected. Transmission INFORMATION

locked to 1st and 2nd gear (Limp-home).
53/04 7F013/11 Analogue input signal, value error. INFORMATION
53/05 7F013/F Analogue input signal, value error. INFORMATION
54/00 7F014/4 Reference voltage sensor 5 V. WARNING
54/01 7F014/3 Reference voltage sensor 5 V. WARNING


56/00 7F016/4 Pressure sensor gear 2/4, short-circuited to ground. Control INFORMATION
unit locks transmission in neutral.
56/01 7F016/3 Pressure sensor gear 2/4, is not connected. Control unit INFORMATION
locks transmission in neutral.
56/04 7F016/11 Pressure sensor gear 2/4, value error. INFORMATION
56/05 7F016/F Pressure sensor gear 2/4, value error. INFORMATION




Description Action
Code SPN/FMI
60/00 7F01A/6 Sensor rpm drum. STOP or WARNING

If several rpm signals or the engine rpm signal are incor-
rect, control unit transmission activates Limp-home.
60/01 7F01A/5 Sensor rpm drum. STOP or WARNING

60/03 7F01A/A Sensor rpm drum, value error. STOP or WARNING
60/04 7F01A/1 Sensor rpm drum, value error. STOP or WARNING
60/05 7F01A/0 Sensor rpm drum, value error. STOP or WARNING
61/00 7F01B/6 Sensor rpm output shaft. STOP or WARNING

61/01 7F01B/5 Sensor rpm output shaft. STOP or WARNING

61/03 7F01B/A Sensor rpm output shaft (B7580), value outside limit STOP or WARNING
values.
61/04 7F01B/1 Sensor rpm output shaft, value error. STOP or WARNING
61/05 7F01B/0 Sensor rpm output shaft, value error. STOP or WARNING
62/00 7F01C/6 Sensor engine rpm. STOP or WARNING

62/01 7F01C/5 Sensor engine rpm. STOP or WARNING

62/03 7F01C/A Engine rpm information not available. Transmission locked STOP or WARNING
to gear 1 and 2 (Limp-home).
62/04 7F01C/1 Sensor engine rpm, value error. STOP or WARNING
62/05 7F01C/0 Sensor engine rpm, value error. STOP or WARNING
62/06 7F07A/1 Incorrect engine rpm information when turbine rpm is calcu- STOP or WARNING
lated. Transmission locked to gear 1 and 2 (Limp-home).

Description Action
Code SPN/FMI
63/00 7F01D/6 Sensor rpm turbine. STOP or WARNING
63/01 7F01D/5 Sensor rpm turbine. STOP or WARNING

63/03 7F01D/A Sensor rpm turbine, value error. STOP or WARNING
63/04 7F01D/1 Sensor rpm turbine, value error. STOP or WARNING
63/05 7F01D/0 Sensor rpm turbine, value error. STOP or WARNING
70/00 7F020/4 Servo valve gear forward and reverse. Transmission locked STOP: Stop the machine and shift to
to gear 1 and 2 (Limp-home). neutral. Select reverse gear.
71/00 7F021/4 Solenoid valve gear selection 1/3. Transmission locked to STOP: Stop the machine and shift to
gear 1 and 2 (Limp-home). neutral. Select reverse gear.

Description Action
Code SPN/FMI
73/00 7F023/4 Analogue output signal. Transmission locked to gear 1 and STOP: Stop the machine and shift to
2 (Limp-home). neutral. Select reverse gear.
74/00 7F024/4 Analogue output signal. WARNING
76/00 7F026/4 Analogue output signal. STOP
77/02 7F02F/1F All gear packs disengaged. Transmission in locked neutral STOP
position (Shut-down).
80/00 7F027/4 Solenoid valve drive. Transmission in locked neutral posi- STOP: Stop the machine and shift to
tion (Shut-down). neutral. Select reverse gear.
81/00 7F028/4 Solenoid valve drive reverse. Transmission locked to gear STOP: Stop the machine and shift to
1 and 2 (Limp-home). neutral. Select reverse gear.

Description Action
Code SPN/FMI
83/00 7F02A/3 Solenoid valve gear selection 2/4. Transmission in locked STOP: Stop the machine and shift to
neutral position (Shut-down). neutral. Select reverse gear.
83/01 7F02A/4 Solenoid valve gear selection 2/4. Transmission in locked STOP: Stop the machine and shift to
neutral position (Shut-down). neutral. Select reverse gear.
90/01 7F0F0/1 Software error, Transmission control unit. -
90/11 7F0F0/B Software error, Transmission control unit. -
90/12 7F0F0/C Software error, Transmission control unit. -
90/13 7F0F0/D Software error, Transmission control unit. -
90/14 7F0F0/E Software error, Transmission control unit. -
90/15 7F0F0/F Software error, Transmission control unit. -
90/90 7F0A0/1F Software error, Transmission control unit. Transmission in STOP


Description Action
Code SPN/FMI
90/xx - 7F000/0 Transmission malfunction. Transmission in locked neutral STOP or INFORMATION
99/xx position (Shut-down).
91/50 7F0F7/A Software error, Transmission control unit. -
91/51 7F0F7/B Software error, Transmission control unit. -
91/52 7F0F7/C Software error, Transmission control unit. -
91/53 7F0F7/D Software error, Transmission control unit. -
91/54 7F0F7/E Software error, Transmission control unit. -
91/55 7F0F7/F Software error, Transmission control unit. -
91/70 7F0F7/1E Software error, Transmission control unit. -
92/00 7F0F2/0 Software error, Transmission control unit. STOP
92/01 7F0F2/1 Shifting missing direction. Transmission locked in neutral STOP

92/02 7F0F2/2 Doubled direction. Transmission locked in neutral position STOP

(Shut-down).
92/03 7F0F2/3 Doubled gear. Transmission locked in neutral position STOP

(Shut-down).
92/04 7F0F2/4 Doubled shock pattern. Transmission locked in neutral po- STOP
sition (Shut-down).
92/06 7F0F2/6 Signal error. Transmission locked in neutral position STOP

(Shut-down).
92/07 7F0F2/7 Gear selector’s position. Transmission locked in neutral po- STOP
sition (Shut-down).

Description Action
Code SPN/FMI
(Shut-down).

(Shut-down).
92/10 7F0F2/A Signal error. Transmission locked in neutral position STOP

(Shut-down).
92/11 7F0F2/B Signal error. Transmission locked in neutral position STOP

(Shut-down).
92/12 7F0F2/C Signal error. Transmission locked in neutral position STOP

(Shut-down).
92/13 7F0F2/D Signal error. Transmission locked in neutral position (Shut- STOP
down).
92/14 7F0F2/E Signal error speed sensor 1-2. Transmission locked in neu- STOP
tral position (Shut-down).
92/15 7F0F2/F Signal error speed sensor 3. Transmission locked in neutral STOP
92/16 7F0F2/10 Signal error in speed sensor. Transmission locked in neu- STOP
tral position (Shut-down).
92/17 7F0F2/11 Wrong feed voltage. Transmission locked in neutral posi- STOP
tion (Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).
92/30 7F0F2/1E Wrong configuration. Transmission locked in neutral posi- STOP

tion (Shut-down).
93/00 7F0F3/0 Wrong initiation. Transmission locked in neutral position STOP: Switch off the machine and
(Shut-down). the main electrical power.

Description Action
Code SPN/FMI
93/10 7F0F3/A Memory error, Transmission control unit. STOP: Switch off the machine and
the main electrical power.
93/11 7F0F3/B Memory error, Transmission control unit. STOP: Switch off the machine and
the main electrical power.
94/00 7F0F4/0 Wrong initiation. Transmission locked in neutral position -

(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).

(Shut-down).
95/00 7F0F5/0 - STOP
95/70 7F0F5/14 Software error, Transmission control unit. Transmission in STOP

95/71 7F09B/1F Control unit cannot interpret input data. Transmission STOP
locked in neutral position (Shut-down).
99/90 7F0F6/0 Incorrect software in control unit. STOP

Description Action
Code SPN/FMI
99/95 7F0CA/1F Communication error, Transmission control unit. STOP
E.1.01 7F0FA - Calibration error. INFORMATION

-05 7F0FD

7F0FD/6

-09 7F0FD

7F0FD/A

-13 7F0FD

7F0FD/E

7F0FD

7F0FD/10

-24 7F0FD

7F0FD/19

7F0FD/1A

7F0FD

7F0FD/1C

7F0FD/1D

-05 7F0FD

Description Action
Code SPN/FMI
7F0FD/6

-09 7F0FD

7F0FD/A

-13 7F0FD

7F0FD/E

7F0FD

7F0FD/10

-24 7F0FD

7F0FD/19

7F0FD/1A

7F0FD

7F0FD/1C
E.229 7F0FA - Calibration error. INFORMATION

7F0FD/1D

-05 7F0FD

7F0FD/6

-09 7F0FD

7F0FD/A

-13 7F0FD

Description Action
Code SPN/FMI
7F0FD/E

7F0FD

7F0FD/10

-24 7F0FD

7F0FD/19

7F0FD/1A

7F0FD

7F0FD/1C

7F0FD/1D
E0/01 7F0E1/F Machine’s speed is too high to enable downshift. INFORMATION
E1/01 7F0E2/F Machine speed is too high to enable change of travel INFORMATION
direction.
E2/01 7F0E3/F Engine rpm is too high to enable change of travel direction INFORMATION
or select same travel direction again.
E3/00 7F0E4/E Machine’s speed limitation is activated. INFORMATION
E3/01 7F0E4/F Machine’s speed limitation is activated regardless of if INFORMATION

speed is above the limit value.
E3/02 7F0E4/10 Machine’s speed is higher than the upper limit value. INFORMATION
E4/00 7F0E5/11 Abnormal speed reduction. The transmission disconnects INFORMATION

automatic gearing for a time.
E4/01 7F0E5/F Abnormal acceleration. The transmission disconnects au- INFORMATION

tomatic gearing for a time.
E5/01 7F0E0/D Time for calibration reached. Calibrate the transmission.
E6/00 7F0E6/1F The operator is not sitting in the operator’s seat and the INFORMATION
gear selector is not in neutral and/or the parking brake is not
activated.

Description Action
Code SPN/FMI
E7/01 7F0E7/F Turbine rpm exceeds limit value. Transmission control unit INFORMATION
forces engine to idle.
E8/01 7F0E8/F Conditions for shifting between 2WD and 4WD are not ful- INFORMATION
filled. Machine must be at a standstill.
E9/01 7F0E9/F Conditions for shifting between High and Low are not ful- INFORMATION
filled. Machine must be at a standstill.
xx/49 - Undefined failure. STOP
Control unit transmission can generate two states with reduced func-
tionality to protect the transmission in the event of serious
malfunctions:
• Limp-home
In this state, only gears 1-2 can be used in both directions. If the
malfunction occurs at a higher gear, manual downshifting is re-
quired to gear 1 or 2.
• Shut-down
In this mode the transmission is permanently in neutral as there is
no oil pressure to enable gear selection.
Table 5. Error codes ZF 5WG261
Description Action
Code ZF-
(dec) code
(hex)
37 25 Sensor oil temperature sump transmission. -
38 26 Sensor oil temperature sump transmission. -
39 27 Sensor oil temperature transmission. -
40 28 Sensor oil temperature transmission. -
49 31 Sensor engine rpm. Hard shifting. -
52 34 Sensor rpm turbine. Hard shifting. -

If any of error codes 52-54, 62, are set at the same time the trans-
mission locks in neutral (shutdown).

Description Action
Code ZF-
(dec) code
(hex)

55 37 Sensor rpm drum. Hard shifting. -
58 3A Sensor rpm output shaft. Hard shifting. -

If any of error codes 58-60, are set at the same time the trans-
59 3B Sensor rpm output shaft. Hard shifting. -

60 3C Sensor rpm output shaft. Hard shifting. -

62 3E Sensor rpm output shaft. Hard shifting. WARNING: Stop the machine, se-
If any of error codes 52-54 are set at the same time the transmis- lect neutral. Select gear again.
sion shifts to neutral (Limp-home).
84 54 CAN-message Control unit KID (D795) -
85 55 CAN-message Control unit cab (D790-1) -
86 56 CAN-message Control unit engine (D794). Hard shifting. -
89 59 Logic error, CAN-messages. -
97 61 Incorrect CAN-messages. -
113 71 Solenoid valve clutch K1. Transmission shifts to neutral WARNING: Stop the machine, se-
(Limp-home). lect neutral. Select gear again.
In case of malfunction of several clutches: Transmission locked
in neutral (shutdown).

Description Action
Code ZF-
(dec) code
(hex)

Description Action
Code ZF-
(dec) code
(hex)
132 84 Solenoid valve clutch KV. Transmission shifts to neutral WARNING: Stop the machine, se-
135 87 Solenoid valve clutch KR. Transmission shifts to neutral WARNING: Stop the machine, se-
177 B1 Clutch K1 slips. Transmission shifts to neutral (Limp-home). WARNING: Stop the machine, se-
In case of malfunction of several clutches: Transmission locked lect neutral. Select gear again.

Description Action
Code ZF-
(dec) code
(hex)
181 B5 Clutch KV slips. Transmission shifts to neutral (Limp-home). WARNING: Stop the machine, se-
182 B6 Clutch KR slips. Transmission shifts to neutral (Limp-home). WARNING: Stop the machine, se-
183 B7 Transmission oil temperature sump above 100 C. WARNING: Note the error and try
to reduce temperature in torque
converter by operating calmly.
186 BA Sensor transmission oil filter (B755-5). Change oil filter.
188 BC Speed limitation exceeded. -
194 C2 Torque limit input shaft too high. -
195 C3 Transmission oil temperature torque converter above 120 C. WARNING: Stop the machine, en-
gage neutral, and apply full throttle
(limited to 50%) to cool the trans-
mission oil so that temperature
drops below 100 C.
When temperature in torque con-
verter is below 100 C, resume
work with machine.
209 D1 Voltage feed to sensor. -
210 D2 Voltage feed to sensor. -
211 D3 Low battery voltage. Transmission locked in neutral (shutdown). Check alternator and battery as
well as cable harness between
battery and alternator.
212 D4 High battery voltage. Transmission locked in neutral (shutdown). Check alternator and battery.
If equipment for assisted start is
connected, disconnect it.

Description Action
Code ZF-
(dec) code
(hex)
213 D5 Solenoid valve VPS 1. Transmission locked in neutral -
(shutdown).
214 D6 Solenoid valve VPS 2. Transmission locked in neutral -

(shutdown).
227 E3 Incorrect CAN-messages. Transmission shifts to neutral WARNING: Stop the machine, se-
241 F1 Memory error Control unit transmission (D793). Transmission -

locked in neutral (shutdown).
242 F2 Program error Control unit transmission (D793). Transmission -

243 F3 Program error Control unit transmission (D793). Transmission -

245 F5 Clutch malfunction when calibrating. Transmission locked in -

neutral (shutdown).
246 F6 Calibration data incorrect. -

For serious transmission malfunctions the control unit uses four

modes with reduced functionality to protect the transmission from
damage. These are:
• "Substitute clutch control".
In this mode, the operator can use the machine as normal. How-
ever, gearshifting and change of travel direction take place while
controlling normal modulation. The control unit uses standard val-
ues for modulation of the clutches.
• "Limp home".
In this mode, the operator can use one of the transmission’s gears
in both directions, and in some cases only in one travel direction.
In order to continue driving with an error with the "Limp home" lim-
itation the machine must be stopped and then stationary, and the
gear selector moved to neutral before the gear can be reselected.
• "Transmission shut down".
In this mode the transmission is permanently in neutral position
when the solenoid valves for the clutches and parts of the voltage
feed to the transmission are switched off. Park the machine and
switch off the engine.
• "TCU shut down".
In this mode the transmission is permanently in neutral position
when all solenoid valves and all voltage feed to the transmission
are switched off. Park the machine and switch off the engine.

5 Handling – 5.4 Operating 139
5.4 Operating
5.4.1 While operating
General
page
–
DANGER
The machine’s work area is large and visibility from
the operator’s cab is restricted.

ty damage!
Keep in mind:
• Always check that no persons are in the way of the

machine or its accessories. Also check that the
area upwards is free. Stop the machine if there are
unauthorised persons or vehicles within the work
area.
• The operator must always face in the travel direc-

tion and should operate with special care where
persons or vehicles may appear.
• The operator must adapt the speed to the load and

ground conditions, visibility, and wind conditions,
etc.
• The operator must pay extra attention and operate

with special care near electric power lines, via-
ducts, docksides, ramps, doorways, etc.
• Always operate carefully so that the attachment

• Use available visibility-enhancing equipment

such as rear view mirrors and camera .
WARNING
ly inspection.
For work instruction, see section 6.1 Daily inspection.

Notify the foreman/supervisor if defects are found on
the machine during daily inspection!

140 5 Handling – 5.4.1 While operating
WARNING
Never operate the machine without wearing the
seatbelt.
Extreme danger!
Always use the seatbelt when operating the machine,

even when you expect a short shift. The seatbelt may
not be modified.
Instructions
–
Make a habit of checking the following at regular intervals while

51 52 operating:
• that coolant temperature is within the interval (approx. 75-85 °C).
• that fuel indicator on the display shows that there is fuel in the
tank.
NOTE
The fuel indicator should never go down to empty tank.
• that all warning lights are off.
• that horn, lighting, brake lights and direction indicators function
correctly.
• that all hydraulic functions function correctly.
006494
• that no error codes have been generated (shown on operator’s

display with error code indication and symbol). See section 5.3
51. Display for control and monitoring system
Error codes.
52. Indicator for control and monitoring system, STOP
or WARNING When necessary, the control system can set speed limitations for the
machine. This happens at:
• high load on steering axle (overload on steering axle)
• lock of tilt or levelling

• pressed down control breaker
• transport with bottom lift, see Transporting load page 158
• raised cab, see Functions for load handling page 163 .

5 Handling – 5.4.2 Starting engine 141
5.4.2 Starting engine

General
page
–
WARNING
If it’s difficult to start the engine, do not use start
spray.
Risk of explosion!
In case of start problems, contact service.
Instructions
–
1. Set the gear selector and multi-function lever in neutral position.

Gear selector and multi-function lever must be in neutral, other-
wise engine cannot be started.
2. Turn the start key to operating position, position I.
Current is now supplied to all electrical functions.
3. Turn the start key to preheating position, position II.
In case of cold weather, preheating can be used. During preheat-
ing the engine’s inlet air is preheated using a heating coil to a suit-
able temperature to facilitate start.
For engine alternative Volvo TAD1250VE and Volvo
TWD1240VE: If needed, the engine’s control unit activates pre-
heating for a time period. The light for preheating (position 39) in-
dicates if preheating is activated.
Engine can be started, position III (start position), regardless of if
preheating is in progress, not activated (no need) or has been
finished.
Engine alternative Cummins QSM11 does not have preheating.
4. Turn the start key to start position, position III.
Let the starter motor crank engine, release the key when engine
starts. The machine has electric restart interlock that protects the
starter motor from engaging when the engine is rotating.
Note that some warning or indicator light may remain on after start
to indicate status. The light for preheating may remain on for
awhile during operation in cold weather, as preheating may be ac-
tive during initial operation.
NOTE
IF THE ENGINE DOESN’T START, try again after
15-20 seconds. Don’t run the starter motor for longer than
10 seconds at each start attempt.
If the engine still doesn’t start, this indicates that there is a
malfunction which has to be located and repaired. Contact
service.

142 5 Handling – 5.4.3 Warming up
5.4.3 Warming up
General
page
–
CAUTION
Never rev a cold engine at high engine speeds.
Risk of engine damage!
Run the engine at 1400-1500 rpm until it starts to get

warm.
Instructions
–
In case of extremely cold weather, the machine must not used in tough
work before operating temperature has been reached.
• It is very important that the engine oil is warmed up and circulates
well before the turbocharger starts to operate at high revolutions.
• Start working with the machine when the coolant has reached nor-
mal operating temperature (approx. 75 °C).
• Warm up the hydraulic oil. Run hydraulic functions without load for
a short time before starting to work.

5 Handling – 5.4.4 Gearshifting 143
5.4.4 Gearshifting
General
page
–
The machine is equipped with an automatic transmission. The system

shifts to a higher/lower gear under certain conditions such as torque,
engine rpm, travel speed, etc.
F
General about the automatic transmission:
• Has a built-in control and monitoring system, providing optimal
operation.
• Shows current gear on the control system display.
R 64
• Reverse lock-out prevents change of travel direction taking place
63
too fast, that is, prevents eventual transmission damage. Reverse
006495
62 lock-out is automatic and depends on engine rpm and travel
62. Switch for shifting program A speed.
63. Switch for shifting program 1 • Shifting is variable (modulated) and gives smoother operation.
64. Switch for shifting program 2 Normally start takes place in 2nd gear. Use of 1st gear is control-
led by, e.g., engine speed.
Instructions
–
1. Let the engine idle. Select travel direction, move lever forward (F)
or backward (R).
2. Select shifting program: A, 1 or 2.
The operator can limit gearshifting by selecting shifting program
on the steering wheel panel’s keys.
Shifting program A (position 62) – automatic shifting between all
gears.
Shifting program 1 (position 63) – gear is locked to 1st gear.
Shifting program 2 (position 64) – gear is locked to 2nd gear.
NOTE
In certain circumstances, the transmission may be forced to
reduce speed due to a problem. The control unit may then
put the transmission in "limp home" mode.

144 5 Handling – 5.4.4 Gearshifting
Transmission assumes neutral position

–
A breaker senses when the operator leaves the operator’s station. The
signal from the breaker means that the transmission automatically as-
sumes neutral position. It is not possible to select any travel direction.
008191
Breaker in operator’s seat
NOTE
If the buzzer sounds when the operator sits in the seat and re-
leases the parking brake then the control breaker in the seat may
be malfunctioning. It is not possible to select a travel direction.
The machine can be operated in emergency mode by means of
by-passing the safety system (override). Activate the by-pass
switch (76), select travel direction and drive the machine to the
workshop. Speed is limited to 10 km/h.
76
WARNING
010909
76. Switch for by-passing

No safety system is engaged!

5 Handling – 5.4.5 Steering 145
5.4.5 Steering
General
page
–
The machine is equipped with servo steering. The steering wheel

movements are transferred hydraulically to the steering wheels on the
ground.
WARNING
The machine may not roll on a downhill grade if the
engine is off.
Hydraulic pressure for steering is missing and steer-

ing capacity is lost! Danger!
Keep the engine running for hydraulic pressure.
5.4.6 Service brake

General
page
–
The brake pedal (position 12) used as service brake.

Use the brakes in a smooth but firm way. Brake pressure remains for
awhile after the engine has been turned off, accumulated during oper-
ation. If the accumulator pressure drops below a certain level, the in-
dicator light for low brake pressure (position 33) is activated on the
panel. When the light is activated the service brake’s capacity is limit-
ed. The buzzer sounds and speed is limited. Finally, the parking brake
is applied automatically by a forceful spring in the brake cylinder.
Check the sealing integrity of the accumulators if the pressure is not
built up and maintained, see section 6 Inspection and maintenance.
The brake pedal is combined with a separate clutch pedal
(position 13). When the brake and clutch pedals are pressed down at
the same time, the transmission is disengaged. Before drive is disen-
gaged, the drive functions as an engine brake.
000340
12 13 12 11
11. Accelerator (throttle pedal)
12. Brake pedals
13. Clutch pedal

146 5 Handling – 5.4.7 Parking brake
5.4.7 Parking brake

General
page
–
DANGER
The parking brake should not be applied when the ma-
chine is in motion.
Very sudden braking. Risk of machine tipping over,

load tipping over or being dropped, or damage to
property or extreme danger!
Stop the machine before applying the parking brake.
WARNING
Never leave the operator’s station without first apply-
ing the parking brake.
Risk of machine starting to roll! Danger!
Apply the parking brake before leaving the operator’s

station.
The parking brake is operated with the switch (position 8) on the panel
for hydraulic functions (position 6). The indicator light for parking brake
(position 46) is activated with a red light when the parking brake is
applied.

5 Handling – 5.4.7 Parking brake 147
Instructions
–
The parking brake is applied when:

• The switch for parking brake is pressed down (indicator light for
parking brake is activated with a red light).
• The ignition is turned off (to 0 position).
When the ignition is switched on again, the parking brake is ap-
30-35
plied without the switch for parking brake being activated. The in-
dicator light for parking brake flashes to indicate that the parking
brake switch should be turned on and then off to release the park-
ing brake. Check the accumulators for leaks if pressure is not built
up and maintained; see chapter 6 Inspection and maintenance.
8 An audible signal is activated if the operator gets up from the driver’s
seat without first applying the parking brake.
If the accumulator pressure drops below a certain level, the warning
33 46
lamp for low brake pressure is activated (position 33). The service
brake’s capacity is limited when the light is activated. Finally, the park-
ing brake is applied automatically by a forceful spring in the brake
cylinder.
If the machine has to be moved, see section 7 Transporting the
machine.
004667
8. Switch for parking brake

33. Warning lamp for low brake pressure
46. Indicator light for parking brake
Emergency brake
–
The parking brake can be used as emergency brake in emergency

situations.
CAUTION
The parking brake can be used as an EMERGENCY
BRAKE.
Brake pads wear out and lose their braking perform-

ance! Unwanted movement of parked machine!
Following emergency braking with the parking brake,

check the brake pads as soon as possible, change if
necessary! Braking action of the parking brake may
be lost as the brake pads may have been worn down.
If the parking brake has been released mechanically

then it must always be reset to restore the machine’s
parking brake function.

148 5 Handling – 5.4.8 Heating / Air conditioning
5.4.8 Heating / Air conditioning

General
page
–
Heating (EHC) / climate control unit (ECC) receives heat from the en-
A gine’s cooling system and gives heat when the engine is warm. For
ECC, cooling performance is generated by the AC compressor.
The system is controlled by switches for fan, heat and air distribution.
In addition, there are functions for recirculation and defroster.
For ECC: In case of open door, the air conditioning’s AC compressor
is turned off (cooling function and air drying stops). Close the door and
the AC compressor is reactivated.
18
17
004690
16
A. Panel nozzle
16. Switch for fan
17. Switch for heat
18. Switch for air distribution

5 Handling – 5.4.8 Heating / Air conditioning 149
Normal weather conditions

–
1 Set desired temperature (position 17).

Set the temperature within temperature range 16 °C to 27 °C.
See position B on display.
Setting of min. and max. respectively, shuts off automatic climate
control (control of fan, temperature and air distribution) and sets
the heat valve in min. and max. position, respectively.
004918
2 Switch (green) for fan handles setting of fan speed for the cab.
Fan speed can be set for:
• automatic control, AUTO. See position C on display.
• manual control in 13 steps from off to max. Fan speed is
shown by the bar’s height in the operating menu for heating
/ air conditioning system. See position C on display.
Recommendation: Set the fan to automatic control, AUTO, for
C
optimal function of the system. Automatic control is activated
when lowering with the switch from fan off.
004919
C
NOTE
When the fan is off, the cooling functions ceases (for ECC).
3 Set air distribution (position 18) and panel nozzles as desired for
a comfortable operator climate. See position E on display.
4 Normally, recirculation (function key for Enter) and defroster (po-
sition 54) do not have to be used.
Defroster - position D on display
Recirculation - position F on display
D
E
F
004920

150 5 Handling – 5.4.8 Heating / Air conditioning
Mist on windows
–
1 Set a warm temperature (position 17).

2 Set a fan speed to a faster position (position 16).
3 Set air distribution (position 18) and panel nozzles (position A) at
the windscreen to get good visibility through the windows.
A
004915
4 Check that recirculation is not engaged. Recirculation may impair

effective demisting.
The symbol for recirculation shall not be shown in the information
menu for heating / air conditioning. See position H on display.
G
To activate/deactivate recirculation, press on the function key for
Enter when the operating menu is shown. See position G.
H
004917
5 Activate defroster (position 54).

The defroster controls the function fan, temperature and damper
position to optimally heat and faster dry the air at the front wind-
shield for faster demisting. The function is active for 6 minutes.
The symbol for defroster is shown in the operating menu for heat-
I ing / air conditioning, and is indicated in the switch. See position I
on display.
NOTE
004921
The defroster function is active for 6 minutes.

Check that temperature control returns to set value when
the defroster is turned off.
6 If there is a lot of mist, direct the panel nozzles (position A) to the
windscreen for optimal demisting.

5 Handling – 5.4.9 Stopping engine – parking 151
5.4.9 Stopping engine – parking

General
page
–
NOTE
Never disconnect the main electric power with the battery discon-
nector when the engine is running! The voltage regulator may be
damaged.
Instructions
–
1. Stop the machine and move the gear selector and multi-function
lever to neutral position.
2. Apply the parking brake.
3. Run in the boom completely and lower it to its lowest position.
4. For hydraulic sliding cab or hydraulic vertically adjustable cab
: Return the cab to its original position.
5. Let the engine run 1 minute at idle speed before stopping the en-
gine so that the engine cools down slightly and the turbo bearings
are lubricated.
6. Stop the engine by turning the start key to position 0.
In case the machine is going to be parked for a long time, the bat-
tery disconnector should be turned to the OFF (0) position.
When idling:
• The engine is switched off at idle running for longer than 10 to
30 minutes (adjustable).
• Work lights are switched off after 5 minutes.
• Extra work lights are switched off after 2 minutes.

152 5 Handling – 5.5 Load handling
5.5 Load handling

General
page
–
During all lifting work, make sure that the max. lift capacity is not ex-
ceeded, see machine plate or load diagram.
The reachstacker’s capacity is indicated by two parameters:
• number of containers in height
• load size and its centre of gravity in relation to the machine
The capacity varies between models and versions, see the machine
and type plates, section 3.2 Plates.
It’s important to estimate the position of the centre of gravity. If the ma-
chine appears to be side-heavy, the load should be lowered and ad-
justed with side shift so that the load’s centre of gravity is moved to a
position along the machine’s centre line.
000364
The load handling function refers to, for example, lifting, lowering, ro-
tating, angling and holding a load. Load handling also includes help
functions when handling loads, for example, support jacks.
Load handling subfunctions.
003681
• Lift/lower
Lift and lower

• Extension
003682
Extension
• Side shift
001113
Side shift
• Spreading (positioning)
Automatic spreading 20’ to 40’

001114
30’ stop
Spreading (positioning)

5 Handling – 5.5 Load handling 153
• Rotation
Rotation stop ±25°
003683
Rotation
• Damping
Damping with tilt lock
003684
Damping with adjustable tilt
Tilt Damping with adjustable tilt and tilt lock

• Mechanical levelling 5 
Hydraulic levelling
001117
Levelling
• Twistlocks
004868
Twistlocks
Overload system
–
The machine is equipped with a warning system, LLMC (Longitudinal

Load Moment Control). The warning system shall ALWAYS be func-
tional! The system is used for stationary load handling, in order to not
jeopardise the machine’s stability in the forward direction.
When the machine approaches the stability limit, the following takes
place:
• buzzer in the cab sounds (indication to operator)
See section 2.1 Safety and emergency equipment.
• warning figure is shown on the display (indication to operator)
See section 4.11.2 Event-controlled information.
• boom movement is interrupted.
In this position the boom, and thus the load, can only be retracted
until the buzzer stops sounding and the display figure disappears.
NOTE
Retract the boom before it is lowered! Applies to all load handling!
LLMC is not intended for controlling lateral stability or stability during
operation. As well, it does not take sloping ground conditions into
consideration.
For advice on handling the machine, see section 2.4 Keep in mind.

154 5 Handling – 5.5.1 Lifting load
5.5.1 Lifting load

General
page
–
There are two types of attachments which differ in lift handling:

• top lift attachment
For a top lift attachment, the attachment must be aligned with all
four corners against the container both when locking and releas-
ing the twistlocks. When releasing, the container must stand se-
curely with all four corners on the ground surface.
• bottom lift attachment
For a bottom lift attachment, all four legs must be in clamping po-
sition and be aligned with the load before starting to lift.
WARNING
Do not use a machine where the indicator lights are
out of order.
Danger of reduced safety during load handling!
If the indicator lights don’t work, stop work with the

machine and repair.
WARNING
The machine’s load capacity is limited.
It is prohibited to exceed the machine’s load capacity.

See marking plate and load diagram. The machine’s
stability limit may be exceeded if the overload protec-
tion system is not working.

5 Handling – 5.5.1 Lifting load 155
Instructions for top lift attachment

–
1 Run the machine forward towards the stack of containers, as

A B C close as possible. Strive to line up the machine’s centre with the
centre of the container.
2 Hold the machine still with the footbrake and clutch-release ped-
al. Alternatively, apply the parking brake if required and/or shift to
neutral.
000365
3 Place the attachment slightly above the container. Adjust with ro-
A B C tation, side shift and boom in/out.
4 Set spreading to container length in question.
Right light, C – Twistlocks unlocked, red light activated, indicates
that load is not secured.
000366
5 Lower the attachment on the container.
A B C The display shows a symbol for alignment. Speed of lowering is

reduced automatically when the attachment gets close to the
container.
000367
000468
6 Middle light, B – Alignment, orange light activated, indicates

when all four corner boxes have correct alignment against the
container.
7 Lock twistlocks with the switch for twistlocks (position 69).
If automatic locking of twistlocks is used, locking is automatic
when the attachment is aligned with the load.
Locking alternative is selected with the switch for automatic or
manual locking (position 69).
NOTE
For automatic locking of twistlocks, the parking brake must
be released.

156 5 Handling – 5.5.1 Lifting load
8 Right light, C – Twistlocks unlocked, off.

Left light, A – Twistlocks locked, is activated with green light and
indicates that load is secured and ready for lifting.
The lift function is disconnected when both right light, C – Twist-
locks unlocked, and left light, A – Twistlocks locked, are off. Left
light, A – Twistlocks locked, is activated with green light when the
locking process has been completed.
CAUTION
Do not start to lift if light C "Twistlocks unlocked" is
on, or if any of the lights A "Twistlocks locked" or B
"Alignment" are off.
The load is not secured!
Try to lock twistlocks once again.
9 Ready for lifting.

When the container is lifted the light (position B) for alignment
shall turn off. Use side shift to centre the load so that its lateral
point-of-gravity is along the machine’s centre line.
Instructions for bottom lift attachment

–
1 Lower the rear leg pair.

D E H I
Light I – Front leg pair raised, white light activated, indicates that
F G J K front leg pair is raised.
2 Place the attachment’s rear legs slightly under the load. Adjust
with rotation, side shift and boom in/out.
3 Run the machine forward towards the load until clamping position
is indicated for rear leg pair. Strive to line up the machine’s centre
with the centre of the load.
Light J – Clamping position rear leg pair, orange light activated,
000418
indicates when rear leg pair has clamping position against load.
4 Hold the machine still with the footbrake and clutch-release ped-
D E H I al. Alternatively, apply the parking brake if required and/or shift to
neutral.
F G J K
000419

5 Handling – 5.5.1 Lifting load 157
5 Lower front leg pair.

D E H I
Light K – Front leg pair lowered, orange light activated, indicates
F G J K that legs are lowered.
6 Secure load by setting legs in clamping position.
Lights H and J – Clamping position front and rear leg pair, yellow
lights activated, indicate clamping position.
Light K indicates that front legs are lowered.
000420
7 Ready for lifting.
D E H I
When load is lifted, lights D, E, F and G – Alignment legs against
F G J K load, should light up within 4 seconds.
Lights H, I, J and K are off at full alignment of rear leg pair against
the load, that is, lights H and J – Clamping position front and rear
leg pair, and light K – Front legs lowered, go off.
NOTE
Lights D, E, F and G must be activated within 4 seconds
000421
when lifting, otherwise the lift attempt is aborted. Lower load

to the ground. Lights D, E, F, G, H and J must be unaffected
before a new lift attempt is made.
Instructions for lifting with slings

–
Attachment points or hooks are located at each twistlock/corner box

on the attachment. These are used in conjunction with lifting slings.
The maximum weight when lifting with "slings" is 40 tonnes.
Bear in mind the following when lifting with slings:
• The equipment used to lift with slings must be the correct size as
well as approved for such usage and the load to be lifted.
• Use slings that are as short as possible.
• The load must always be lifted vertically using all four corners with
the load equally distributed to the four lifting points (see figure).
Max 15˚ • When lifting and transporting a load hanging in "slings", drive
slowly (below 5 km/h) and pay close attention to the position of the
load.
002564

158 5 Handling – 5.5.2 Transporting load
5.5.2 Transporting load

General
page
–
WARNING
Transporting loads is associated with major risks.
Risk of roll-over and tipping! Risk of load damage to

property!
Respect the lifting capacity of the machine and exer-

cise the greatest caution during load handling:
• The machine shall only be operated on even sur-

faces, intended for the machine’s total weight and
ground pressure.
• All loads should be carried in the transport posi-

tion. Always operate carefully; keep in mind the
width and height so that the boom or attachment
• While being carried the load’s centre of gravity

must always be centred laterally.
• Do not transport the load in high position since

this may cause the machine to roll or tip over.
• Always operate with the load facing uphill on an

uphill or downhill grade, never operate or turn
across a grade.
• Operate the machine in reverse if the transported

load obscures visibility to the front.
• No personnel may encroach or stand under a

raised load.
• The operator must avoid forceful acceleration and

sudden braking.
• The operator must always adjust the speed when

turning to prevent skidding and risk of roll-over.
In the event that the machine rolls over or tips,

hold onto the steering wheel and always stay in
the cab. Do NOT try to jump out of the cab until the
machine has stopped moving.
Local regulations may apply when handling spe-

cial loads. Learn about them and follow them.
Note that the illustrations in this section show transport with top lift at-
tachment and container. Instructions also apply to transport with bot-
tom lift attachment and load.

5 Handling – 5.5.2 Transporting load 159
Instructions for top lift and bottom lift

–
1 Lift the load slightly. Back away from the stack.

D E H I Top lift: when load is lifted, the middle light, B – Alignment, (or-
F G J K ange), is off. Then the function for twistlocks is disconnected.
Bottom lift: when lifting, lights D, E, F, and G for alignment and
clamping position are on. Lights H, I, J and K are not activated at
full alignment of the leg pairs against the load.
A B C
000368
2 Adjust load height and boom to transport position.

D E H I
F G J K
DANGER
Load handling requires extreme care when loading
A B C
and at high load handling height, that is, long boom
extension.
Risk of roll-over! Extreme danger!
When a load is to be lowered, ALWAYS retract the

boom BEFORE the boom is lowered.
000369
3 Correct transport position is with the load as far down and in as

D E H I possible without obstructing visibility, see Transport position
page 160. The load’s centre of gravity should be centred laterally.
F G J K
NOTE
When transporting a load with the OHC-attachment’s folda-
A B C ble extended twistlocks down, the centre of gravity is moved
farther from the attachment’s rotation point. This affects
damping of the attachment. Adjust the speed. If possible, do
not transport loads for long distances with twistlock in low-
ered position.
NOTE
When transporting loads with bottom lift attachment, machine
000370
speed is limited to max. 2nd gear and 10 km/h.

160 5 Handling – 5.5.2 Transporting load
Transport position
–
When the machine is to be operated with a load, transport position

shall be assumed, which minimises the risk of roll-over and imbalance
during operation. In transport position, the boom is completely retract-
ed, the load’s centre of gravity is centred sideways (laterally) and the
load is lifted for good forward visibility (see illustration to the left). All
transport shall take place with the cab in the rear position.
When transporting a load hanging in "slings", drive slowly (below
5 km/h) and pay close attention to the position of the load.
000363
Operating on grades
It is important to operate with extreme care on grades since there’s an
increased risk of tipping and rolling over.
NOTE
When braking, use only the service brake pedal (right-hand brake
pedal). Do not operate service brake in combination with clutch
pedal.
• Operating with a load.
Lower the load as low as possible without compromising visibility.
Retract the boom as far as possible.
Always operate with the load against the grade (see figure), re-
gardless of travel direction.
• Operating without a load.
Lower and retract the boom as far as possible.
Always operate with the attachment in the direction of the grade
(down), regardless of travel direction.
Working near overhead high voltage power lines

Operate with extreme care in all work near overhead high voltage pow-
er lines, keeping in mind the extensive reach capacity of the boom and
005066
attachment.
DANGER
If the machine comes into contact with overhead high
voltage power lines - sit down in the seat and call for
help!
Extreme danger!
Remain in the cab and wait for help.

5 Handling – 5.5.3 Unloading 161
5.5.3 Unloading
General
page
–
There are two types of attachments which differ in lift handling:

• top lift attachment
• bottom lift attachment
Instructions for top lift attachment

–
1 Run towards the stack of containers, as close as possible.
A B C 2 Lift the load over the stack.

Strive to centre the load over the stack. Approach angle towards
container is operator’s choice.
000371
3 Apply the parking brake if desired, or hold the machine stationary

with the service brake and clutch pedal. Alternatively, shift to
A B C
neutral.
4 Position the load over the stack. Adjust with rotation, side shift
and boom in/out.
000372
5 Lower the load.

A B C When alignment is obtained, the middle light, B – Alignment, is
activated.
6 Open twistlocks. Left light, A – Twistlocks locked, goes off (green)
when release of twistlocks is initiated. Right light, C – Twistlocks
unlocked, is activated (red) when twistlocks are completely open.
Never lift when twistlocks are in the process of being released.
000373

162 5 Handling – 5.5.3 Unloading
Instructions for bottom lift attachment

–
1 Run towards the unloading site, as close as possible.

D E H I
2 Lift the load to suitable height.
F G J K Strive to centre the load over the unloading site.
000422
3 Apply the parking brake if desired, or hold the machine stationary
D E H I with the service brake and clutch pedal. Alternatively, shift to
neutral.
F G J K
4 Position the load over the unloading site. Adjust with rotation,
side shift and boom in/out.
000423
5 Lower the load.

D E H I
Alignment of legs against load disappears, which is indicated by
F G J K lights D, E, F and G.
6 Leave clamping position for legs to release load.
Lights H, I, J and K are activated once again when full alignment
of the leg pairs against the load ceases.
Lights H and J are off to indicate that clamping position is no long-
er active.
Lights K is activated to indicate that the front leg pair is lowered.
000424
7 Raise front leg pair.

D E H I
Light K goes off to indicate that the front leg pair is no longer
F G J K lowered.
Light I is activated to indicate that the front leg pair is raised.
8 Back away from the load and raise the rear leg pair.
000425

5 Handling – 5.5.4 Functions for load handling 163
5.5.4 Functions for load handling

Support jacks
page
–
Both support jacks (position B) are mounted at the front in the frame
and their function is to stabilise the machine during load handling. The
support jacks are operated with the switch for support jacks
A
(position A).
The parking brake must be OFF, see indicator light for parking brake.
1 Run toward the load handling site and stop the machine.
2 Lower the support jacks with the switch.
Hold in the switch during the entire movement.
During the movement, the information figure (position C) is
shown on the control and monitoring system’s display. When the
B support jacks are down, this is indicated in the hydraulic panel by
the indicator light for support jacks. The information figure on the
display disappears.
C
3 Carry out load handling.
4 Raise the support jacks with the switch.
The indicator light goes off. During the movement, the informa-
tion figure (position C) is shown. The information figure on the
003685
display disappears when the support jacks have been raised.

A. Switch for vertically adjustable cab For automatic raising / lowering, throttle up (above 1000 rpm) and
press once up / down on the switch for support jacks (position A). For
automatic raising / lowering, AUTO is shown on display.
Hydraulic sliding cab

–
The moveable cab improves visibility during load handling. The cab is
operated with the switch for hydraulic sliding cab (position A).
A The operator’s door(s) must be closed and the control breaker for hy-
2 Move the cab with the switch.
NOTE
003686

Hydraulic sliding cab

164 5 Handling – 5.5.4 Functions for load handling
Hydraulic vertically adjustable cab

–
Hydraulic vertically adjustable cab improves visibility during load han-

dling. The cab is operated with the switch for hydraulic vertical adjust-
A ment of cab (position A).
The operator’s door(s) must be closed and the control breaker for hy-
The left-hand driver’s door is locked when the cab leaves its lowest
position.
1 Close the doors and secure safety chains on the insides of the
doors.
Use the seatbelt.
003687
Hydraulic vertically adjustable cab
3 Move the cab with the switch.

A A mechanical lock prevents the operator from opening the left-
hand door by mistake. The lock releases the driver’s door when
the cab has reached its lowest position.
If the cab is not in the lowest position, that is, raised, the ma-
chine’s speed is limited to max. 2nd gear and 10 km/h.
014270
A. Lock

NOTE
DANGER
When entering under raised cab.
Extreme danger!
A
Secure the cab with the lock lugs (position A) on the
sides of the cab frame.
001977
A. Lock lug
If the cab should jam in the raised position, it can be lowered manually
with an emergency lowering valve, see
Emergency equipment page 84.
Hydraulic cab tilt

–
The tiltable cab simplifies visibility during load handling.

The switch (position 68) is used to select whether the cab shall be tilt-
ed automatically or manually. The switch for manual cab tilt
(position 72) controls manual tilting.
The operator’s door(s) shall be closed and control breaker for hydrau-
014723
lics not activated.
Hydraulic cab tilt

2 With automatic cab tilting active:
The cab is tilted automatically when the attachment is at a prede-
termined lifting height.
For automatic cab tilt, speed must not exceed 5 km/h, operator
doors must be closed and the parking brake not activated.
With manual cab tilting active:
Operate cab tilting with the switch for manual cab tilt (position 72).
To enable manual cab tilt, speed must not exceed 10 km/h, the
driver doors must be closed and the parking brake not activated.
If the cab is not in its lowest position, i.e. tilted, machine speed is
limited to 10 km/h.

NOTE
The cab can only be tilted with closed doors and that boom height
(boom angle) gives room for safe cab tilt.
WARNING
Entering under tilted cab.
Extreme danger!
Check that nobody is under or near the tilted cab. Vis-

ibility is reduced!.
LC-limitation
–
LC-limitation prevents the load from being lifted over the cab (standard
for vertically adjustable cab). When the load reaches a certain dis-
tance from the machine, synchronised lift (lower boom or increase
boom extension) is activated automatically.
Use switch for LC-limitation (position A) for by-passing the
LC-limitation.
WARNING
The load may strike the cab when the LC-limitation
has been by-passed.
Danger! LC-limitation disengaged!
Avoid by-passing the LC-limitation.
A
001927

Rotation stop
–
Rotation stop limits the rotational movement of the attachment ±25°.

When the limit for rotation stop is reached, the rotational movement
stops and the figure is shown on the display.
Use switch for rotation stop (position A) for by-passing rotation stop.
The figure for rotation stop disappears from the display when the rota-
tion of the attachment is within the interval for rotation stop limitation.
A
003688

Height limitation
–
Height limitation limits how high the boom can be raised. The height
limitation is adjustable according to the customer’s needs.
When the boom reaches a certain preset height (position A), the lift
movement is stopped and the figure is shown on the display. Lower or
retract the boom to continue load handling.
A
If there’s a need to lift above the preset height limitation, the function
can be by-passed with the switch for height limitation (position B).
When the height limitation has been passed (grey area in figure, ap-
prox. 70 cm.), lift, lower or extension can be operated without
by-passing.
The figure on the display is always shown when the lift height exceeds
the height limitation.
B
001133

6 Inspection and maintenance 169
6 Inspection and maintenance
6 Inspection and
mm mm mm mm mm mm
maintenance
General
page
–
This chapter describes:

• DAILY INSPECTION – performed by the operator.
Daily inspection describes the running inspection that significantly
contributes to making the machine a safe and reliable workplace.
• MAINTENANCE – performed by the operator.
Maintenance describes some simple maintenance actions.
• SERVICE – performed by trained service technician.
Advanced maintenance is performed according to a service
schedule and by service technicians. Advanced maintenance ac-
tions are described in the maintenance manual.
It is the operator who is responsible for ensuring that the machine
comes in for service according to prescribed service intervals.
Procedures are described in the maintenance manual.
• ERROR CODE INFORMATION – read off by the operator.
Error code information is read off by the operator from the control
system’s display in the cab. Depending on the type of error code,
it is handled by the operator or a service technician.
NOTE
All time information refers to operating time, that is, the time
shown by the hour meter on the panel.
CAUTION
Only spare parts approved by Cargotec may be used.
This is to maintain the machine’s safety as well as to

meet warranty and service agreements!
Only use spare parts and fluids approved by Cargotec

to fulfil warranty terms.

170 6 Inspection and maintenance – 6.1 Daily inspection
6.1 Daily inspection

General
page
–
Daily inspection of the machine is extremely important in order to en-

sure that it is safe both for the operator and its surroundings.
Every operator should perform checks before a new work shift. In this
way, operators can avoid running defective machines with malfunc-
tions that have been generated or caused during an earlier work shift.
WARNING
ly inspection.
Report to the foreman/supervisor if defects are found

on the machine during daily inspection!
Instructions
–
Perform the following checks:

1. Visual external check of the machine. Walk around the machine
and check the following:
• That sensors for twistlocks and alignment are clean and free
from grease
• Leakage from engine, transmission, drive axle, steering cylin-
der, hydraulic hoses and hydraulic cylinders
DANGER
Residue from fuel, oils, grease or other flammable
materials on the engine or in the engine compartment
is a fire hazard.
Fire hazard!
Remove combustible material residue from the en-

gine compartment as soon it is discovered, be espe-
cially careful on hot surfaces such as exhaust
systems, manifolds or turbos. If oil, fuel or coolant
leakage is detected, establish the cause and remedy
before starting the engine.
• Loose wheel studs

Following a wheel replacement, check-tightening of the wheel
studs/bolted joints is very important (after approx. 4-5 operat-
ing hours).

6 Inspection and maintenance – 6.1 Daily inspection 171
• Damage to rims
• Uneven tyre wear – remove any objects that may penetrate
the tyres, e.g. glass, metal filings, etc.
• Tyre pressure
• The lift boom’s mounting points and slide plates with regard
to damage
DANGER
Cracks in materials or welds in load bearing struc-
tures can reduce the machine’s strength.

ty damage!
If there are cracks in materials or welds in load-carry-

ing structures/structural elements, the machine shall
be taken out of use immediately and taken to service.
• Communication equipment – direction indicators, brake

lights, headlights and reflectors with regards to damage
• Cab with regards to damage and dirty windows.
2. Check fluid levels for the following fluids according to description,
see section 6.2 Maintenance. Top up, if necessary, with the cor-
rect fluid:
• Hydraulic oil
• Oil for brake system
• Batteries’ electrolyte level
• Coolant
• Washer fluid – windows
• Engine oil
• Transmission oil
3. Check the engine’s indicator for air filter, also check and drain the
fuel prefilter, when needed. For description, see section 6.2
Maintenance.
4. Start the machine according to instructions and check:
• Instruments – warning lamps, indicators, any error codes on
the display
• Fuel level – the gauge must not show empty tank
• Lighting, direction indicators, horn, brake lights, flashing haz-
ard lights
• Windscreen wipers

172 6 Inspection and maintenance – 6.1 Daily inspection
5. Operate the machine slowly/carefully and check the following

functions:
• Brakes – check-brake at least three times
• Steering – in both directions
• Transmission – all gears – forward and reverse
• Noise from engine, transmission or drive axle
6. Check the attachment’s functions and that:
• Indicator lights for twistlocks and alignment function.
• Contact pins at twistlocks can be moved easily up and down.
Note that a contact pin that binds in the upper position can in-
dicate contact despite the frame not being positioned against
the container.
• Check the function of the twistlocks. This is done by lifting an
empty container until the light "Alignment" goes out. Now, it
shouldn’t be possible to release the twistlocks.
7. Run all functions with hydraulic cylinders (boom lift/lower/in/out
and side shift) to their end-positions for lubrication of the cylinder
barrels and piston rods.
8. For central lubrication

Check that grease has not penetrated out from the safety valve
(position A). This is a sign that the central lubrication is not work-
ing correctly.
9. Check the machine’s operating hours – notify the foreman/super-
visor if the machine is close to a service interval.
A 10. Notify the foreman/supervisor immediately if any defects are de-

tected on the machine.
11. In cold weather:
• check that wiper blades have not frozen to the windscreen
• remove snow from air inlets and radiator grill
• antifreeze in washer fluid
• disconnect the auxiliary heater

006835
Electrical box for auxiliary heater is located by the cab steps

Example figure of unit for central lubrication on the left side of the machine.
12. Check if any error codes are active.
See the section 5.3 Error codes.

6 Inspection and maintenance – 6.2 Maintenance 173
6.2 Maintenance
General
page
–
The following maintenance actions are described in this chapter:

– Cleanliness, general page 175
– Fuel system, general page 177
– Windscreen washer, general page 179
– Air filter engine, general page 180
– Cooling system, general page 181
– Engine oil, general page 183
– Transmission oil, general page 183
– Oil, brake system, general page 185
– Hydraulic system, general page 186
– Tyres and rims, general page 188
– Accumulators, general page 191
– Battery and battery disconnector, general page 192
– Main fuses for electrical system, general page 194
– Fuses for electrical system, general page 195
– Lighting, general page 199
Safety during maintenance

–
Observe the following when maintenance work is to be performed:

• Always turn off the engine during service work. Only exception is
when service work requires engine power.
• No work may be done on the machine without the right knowledge
and skills to do the work correctly. Service performed incorrectly
may be dangerous.
• Always use a hard hat, protective glasses, gloves, work shoes
and other protective items as required by the work situation.
• Read all plates and instructions on the machine and in the opera-
tor’s manual before performing any maintenance. Each one con-
tains important information about handling and service.
• Avoid spills when draining/filling oils and fuel. Use reservoirs/
tanks, pump, hose, etc. for safe handling. Oils and fuels cause en-
vironmental damage and should be taken care of by an authorised
company.
• Always drain the pressure from the accumulators before any work
on the hydraulic system.
• The unit for air inlet to the cab (at front part of cab) is provided with
slip-protection and can be used as a platform to stand on when
performing maintenance by the front part of the cab.

174 6 Inspection and maintenance – 6.2 Maintenance
Cab movement
–
The cab can be moved forward for better visibility and access in the
engine compartment. There is:
• manual cab movement
• hydraulic cab movement
• hydraulic vertically adjustable cab

For hydraulic cab movement, the movement is controlled with a hy-
A draulic function on the panel for hydraulic functions. See chapter 4 In-
struments and controls and chapter 5 Handling.
Instructions for manual cab movement
1. Select neutral gear with gear and multi-function lever.
2. Apply the parking brake.
3. Close the doors.
4. Remove the pin (position B) from the lock handle.
5. Open the lock handle (position C).
Loosen the lock handle on both sides.
000270
6. Push cab forward.

B C
A. Position lock handle
B. Lock pin
C. Lock handle for securing cab
DANGER
The cab is very heavy and the machine must not be
moved without first securing the cab.
Fatal danger! Risk of crushing!
Secure the cab, both sides, with the lock handles and
pins before starting to operate the machine.

6 Inspection and maintenance – 6.2.1 Cleanliness 175
6.2.1 Cleanliness
Cleanliness, general
page
–
Dirt has a negative impact on performance. Experience shows that

clean machines have less malfunctions.
The machine should be washed regularly for optimal function. Keep
the following in mind when washing:
• Use mild cleaning agents.
Use a de-greaser if necessary. Scrub if necessary.
• Use a high-pressure washer, wide water jet.
CAUTION
High-pressure washing of sensitive components may
lead to short-circuiting and cause malfunction.
Product damage!
Do not use a high-pressure washer on the battery

compartment, electric components, control units,
connectors, cable joints, cylinder seals, stub axles,
axle seals and chains.
NOTE
After washing with de-greaser, the hydraulic cylinders should be
run in and out a few times to obtain satisfactory lubrication once
again.
WARNING
reduced in the event of exposure to substances con-
taining aromatic hydrocarbons, ketones, esters or
chlorinated hydrocarbons.
Low strength! Danger!
Check the outside surface of the roof window at reg-

ular intervals. Clean only with windscreen washer flu-
id or a mild cleaning agent. Rinse thoroughly with
plenty of lukewarm water. Replace a damaged roof
window immediately if it’s cracked or scratched!

176 6 Inspection and maintenance – 6.2.1 Cleanliness
CAUTION
Cleaning agents contain different solvents.
Health-hazardous and highly flammable.
Ensure good ventilation when cleaning the machine.

Avoid skin contact, use protective gloves. If you get
dizzy when using cleaning agents, get fresh air imme-
diately and contact a doctor. If the cleaning agent has
found its way into your eyes, rinse immediately with
lots of water and contact a doctor immediately.
CAUTION
Cracks or scratches result in reduced strength of the
roof window.
Low strength!
Replace a damaged roof window immediately.
CAUTION
Objects may shoot off when using compressed air for
cleaning.
Risk of injury.
Use protective goggles and protective gloves. Exer-

cise caution to avoid injury to yourself or those
nearby.
For optimum functionality the machine should also be kept clean in-
side the cab.
• Plastic material: vacuum clean, brush/wipe with lightly moistened
rag. Use mild cleaning agent and always wipe down with a lightly
moistened rag and clean water.
• Textile material: vacuum clean, brush/clean with e.g. furniture or
carpet cleaning agent in accordance with the instructions on the
packaging.

6 Inspection and maintenance – 6.2.2 Fuel system 177
6.2.2 Fuel system

Fuel system, general
page
–
The filler pipe is located on the machine’s left side.
NOTE
Make sure that the area around the tank cap is clean when
refuelling.
WARNING
Fuel is highly flammable and health hazardous.
Fire hazard! Health hazard!
Handle with great care and avoid all possible ignition

sources, for example, cigarettes, sparks.
Avoid skin contact, use protective gloves. In the event
of skin contact and spills on clothes, wash the skin
and change clothes.
006430
A
A. Refuelling point
CAUTION
The quality of the diesel affects the service life of the
engine.
Make sure that correct diesel quality is used.
• Always fill up with diesel fuel.

• Never use additives in the diesel fuel.
• In wintertime, try to fill up immediately after finished operation.
This prevents condensation in the fuel tank. Do not use anti-con-
densation agents, for example, alcohol, in the fuel.
• Do not refuel when the engine is running.
• Make sure that the fuel nozzle is connected securely in the filler
pipe (to prevent spills and generation of static electricity).
• Clean around the filler pipe after refuelling and handle used rags,
wiped up fuel, etc. in an environmentally sound manner.
• For tank volume and fuel quality, see section 9 Specifications.

178 6 Inspection and maintenance – 6.2.2 Fuel system
Fuel prefilter, instructions
NOTE
The water separator should be drained of water every 50 operat-
ing hours.
DANGER
The fuel is highly flammable.
Fire hazard! Extreme danger!
Make sure that open flames, sparks, or red-hot/glow-

Engine alternative Volvo TAD1250VE ing objects have been extinguished before starting
work on or near the fuel system. Do not smoke near
the machine during work on the fuel system.
1 Turn off the system voltage with the battery disconnector.

The engine shall be off.
See Battery and battery disconnector, general page 192.
2 Position a receptacle under the fuel prefilter.
3 Drain the water from the fuel prefilter.
Open the drain cock on the underside, close the cock when clean
fuel drains (no water bubbles).
WARNING
Fuel on hands.
Rash and irritation.
Avoid skin contact with the fuel, use gloves.
Engine alternative Volvo TWD1240VE

4 Remove the collection container. Handle the fuel as environmen-
tally hazardous and fire hazardous waste.

6 Inspection and maintenance – 6.2.3 Windscreen washer 179
Engine alternative Cummins QSM11
6.2.3 Windscreen washer

Windscreen washer, general
page
–
CAUTION
Only use clean water with an antifreeze agent, e.g. an-
tifreeze fluid.
The strength of the roof window may be affected!

A
reduced in case of exposure to substances contain-
ing aromatic hydrocarbons, ketones, esters, or chlo-
rinated hydrocarbons.
The washer fluid reservoir (position A) is located on the left rear on the
cab.
Instructions
• Check the lever in the reservoir. Top up with coolant as needed.
004913
For volume, see section 9 Specifications.

• Add anti-freeze. Select a suitable concentration (dilution water/
A. Washer fluid reservoir anti-freeze fluid) according to the winter conditions and outdoor
temperatures.

180 6 Inspection and maintenance – 6.2.4 Air filter, engine
6.2.4 Air filter, engine

Air filter engine, general
page
–
NOTE
Poorly filtered induction air can very quickly result in serious en-
gine damage.
The filter is changed by the service technician during running inspec-
tions and service. When the machine is used in dusty air, the filter may
A be clogged after a relatively short time.
In the induction system, between the engine and air filter (A), there’s
an indicator (B) which shows red when the air filter is clogged.
The air filter has a dust reservoir (position C) which normally is emp-
tied during operation by vibrations in the induction system. It can also
be emptied manually by shaking it.
Instructions
Check the indicator at regular intervals. Contact service in case the in-
dication is red.
B
012826
A. Position for air filter reservoir

B. Indicator for change
C. Dust reservoir

6 Inspection and maintenance – 6.2.5 Cooling system 181
6.2.5 Cooling system

Cooling system, general
page
–
Coolant is filled in the system’s expansion tank (position A). The cool-
ant level should be between the MIN and MAX markings (position C)
on the expansion tank.
NOTE
Open very carefully as hot coolant may jet up and out.
A If the coolant level becomes too low, the warning lamp for low coolant
level (position 40) lights up on the instrument panel.
NOTE
B A low coolant level may cause engine damage or may cause the
engine to stop.
C
004851
A. Position for expansion tank

B. Filling point Instructions
C. Level marking, MIN and MAX
WARNING
The cooling system is pressurised. Steam or hot cool-
ant may jet out.
Risk of scalding/burn injuries!
Open the filler cap (position B) very carefully when

the engine is warm. Wait until the coolant has cooled
down before topping up.
WARNING
Glycol and anti-corrosion agents are hazardous to
health.
Health hazard!
Handle with care. Avoid skin contact. Wear protective

glasses and protective gloves. In case of skin contact,
wash the skin.

182 6 Inspection and maintenance – 6.2.5 Cooling system
CAUTION
Different types of coolant may not be mixed.
Risk of engine damage if different types of coolant are

mixed.
When changing and topping up coolant, the same

type of coolant must be used as was used before.
• Check the level in the expansion tank. Top up as needed with

ready-mixed recommended coolant. Volvo TWD1240VE is filled
with distilled water, with added at least 40% glycol.
For volume, see chapter 9 Specifications.
IMPORTANT
On machines with ECC or AC it is of the utmost impor-
tance that the engine’s cooling system is refilled with
coolant containing the correct mixture of anti-freeze
fluid, otherwise there is a risk that the air conditioning
could freeze and breakdown when used.

6 Inspection and maintenance – 6.2.6 Engine oil 183
6.2.6 Engine oil

Engine oil, general
page
–
WARNING
The machine uses oils and lubricants.
Health hazard in the event of protracted skin contact!

A Avoid skin contact with oils and lubricants.
Use protective gloves.
The engine’s oil filler pipe (position B) and dipstick (position C) are lo-
cated under the service cover in front of the cab.
Instructions
• Check the oil level (position C).
Check the oil level when the engine is warm. Wipe off the dipstick
before checking.
The dipstick has two markings, MAX and MIN, between which the
oil level should be.
NOTE
The oil dipstick is long. Use gloves.
000378
• Top up as needed with new engine oil (position B). For volume
B C and quality, see chapter 9 Specifications.
A. Position for filling and level check Top up – wait awhile – check on the dipstick.
B. Filling point
C. Dipstick (figure shows dipstick for engine alterna-
tive Volvo TAD1240VE) Engine alternative Volvo
NOTE
TAD1250VE has the dipstick on the right-hand side of Work carefully when filling engine oil to prevent other fluids
the engine and level figure in display. or particles from contaminating the oil. Other fluids or parti-
cles in the engine oil means a risk of engine damage.
6.2.7 Transmission oil

Transmission oil, general
page
–
WARNING
Avoid prolonged skin contact with transmission oil.
Health hazard!
The transmission’s oil filler pipe and dipstick (position B) are located
under the service cover in front of the cab.

184 6 Inspection and maintenance – 6.2.7 Transmission oil
Instructions Dana TE32

• Check the oil level with the engine at idle, transmission in neutral
B C
position and at operating temperature (approx. 60-65 C in the
display). The dipstick has two markings, MAX and MIN. The oil
level should be at MAX.
Wipe off the oil dipstick before checking.
NOTE
The oil dipstick is long. Wear gloves.
• Top up as needed with new transmission oil (position B). For vol-
ume and quality, see section 9 Specifications.
Top up – wait awhile – check on the dipstick.
A
NOTE
Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
013334
particles in the transmission oil means a risk of transmission

damage.
A. Position for filling and level checking
B. Filling
C. Dipstick
Instructions ZF 5WG261
7. Check the oil level with the engine idling and the transmission in
neutral and at operating temperature (80-90 °C on display). Wipe
off the dipstick before checking.
The dipstick has three markings. The bottom is marked "COLD"
and is a rough level estimate for cold transmission. The two upper
are marked "HOT" and are markings for maximum, MAX, and min-
imum, MIN, oil level at operating temperature. The oil level should
be between MIN and MAX. when the transmission is warm and
the engine is idling in neutral.
NOTE
The oil dipstick is long. Use gloves.
8. Top up as needed with new transmission oil. For volume and qual-
ity, see chapter 9 Specifications.
Top up – wait awhile – check on the dipstick.
013047
Oil dipstick and filling point transmission oil NOTE

Work carefully when filling transmission oil to prevent other
fluids or particles from contaminating the oil. Other fluids or
particles in the transmission oil means a risk of transmission
damage.

6 Inspection and maintenance – 6.2.8 Oil, brake system 185
6.2.8 Oil, brake system

Oil, brake system, general
page
–
WARNING
Avoid prolonged skin contact with the oil.
Health hazard!
A
The tank for the brake system is located on the machine’s left side.
Instructions
• Check the oil level (position E).
The level should be in the middle of the sight glass.
• Top up as needed with new oil (position C). For volume and qual-
ity, see section 9 Specifications.
• Check that the oil cooler (position B) isn’t clogged. Clean as
needed.
NOTE
Work carefully when filling brake oil to prevent other fluids or par-
ticles from contaminating the oil. Other fluids or particles in the
brake oil means a risk of damage to the brake system.
000380
B C D E
A. Oil tank for brake system
B. Oil cooler
C. Filling point
D. Breather filter
E. Level glass oil tank

186 6 Inspection and maintenance – 6.2.9 Hydraulic system
6.2.9 Hydraulic system

Hydraulic system, general
page
–
WARNING
Avoid prolonged skin contact with hydraulic oil.
Health hazard!
A B
000381
C D C E F G
A. Position for oil cooler The hydraulic oil tank is located on the machine’s right side.
B. Position for hydraulic tank Instructions
C. Cleaning filter hydraulic oil • Check the oil level (position E). All hydraulic pistons should be in
retracted position (pushed in).
D. Filling point hydraulic tank (spare)
The level should be in the middle of the sight glass.
E. Sight glass hydraulic tank
• Top up as needed with new oil (position F). For volume and qual-
F. Filling point hydraulic tank
ity, see section 9 Specifications.
G. Breather filter
• Check that the oil cooler isn’t clogged. Clean as needed.
NOTE
Work carefully when filling hydraulic oil to prevent other fluids or
particles from contaminating the oil. Other fluids or particles in the
hydraulic oil means a risk of damage to the working hydraulic
system.

6 Inspection and maintenance – 6.2.9 Hydraulic system 187
Emergency lowering of boom

–
As long as there is servo pressure in the hydraulic system, as well as

battery voltage, the boom can be lowered using the control lever in the
cab. In case the hydraulic functions stop working, emergency can take
place with manual control of valves.
NOTE
Operate the boom with constant adjustment of the valves during
the entire boom movement (to use the remaining servo pres-
sure). In case of repeated valve adjustments, the servo pressure
is lost and no functions can be performed.
A
DANGER
Manual operation entails risks!
Risk of crushing, machine tipping/rolling over! Fatal

danger!
Avoid manual lowering. If manual lowering cannot be

avoided, work very carefully.
A Instructions for emergency lowering of boom:

1. Two persons, one on the right and one on the left side of the ma-
C
chine, position themselves to control the solenoid valve for each
B D respective lift cylinder (position A).
2. Turn the control knob to position C, unlocked but closed.
E 3. Turn the control counter-clockwise to open the valve (area B).
000578
This releases pressure in the lift cylinders. NOTE! Perform this at

the same time at both lift cylinders.
A. Control for operating solenoid valve lift cylinder
Boom lowers slowly.
B. Area where valve opens proportionally with the con-
trol’s position When control knob is released, the control knob returns to closed,
C. Valve closed (unlocked) position C.
D. Area where valve is closed 4. When lowering is finished, turn the control knob to position E.
E. Valve closed (locked)

188 6 Inspection and maintenance – 6.2.10 Tyres and rims
6.2.10 Tyres and rims

Tyres and rims, general
page
–
DANGER
Changing tyres is high-risk work.
Extreme danger!
Let service personnel change tyres, they have the

competence and authority to handle tyres!
DANGER
Penetrating objects such as crushed glass, pieces of
wood, metal shavings, etc. and mechanical defects,
such as uneven brake wear, can cause tyre damage.
Risk of tyre explosion! Extreme danger!
Check the tyres at regular intervals for external dam-

age and tyre pressure.
WARNING
Check-tighten the wheel nuts on a new wheel after
4-5 operating hours.

ty damage!
Tighten bolted joints crosswise. Contact a service

technician as needed.
CAUTION
Spare and replacement tyres should be of brand
names approved by Cargotec.
Risk of overloaded tyres!
Use tyres approved by Cargotec.

6 Inspection and maintenance – 6.2.10 Tyres and rims 189
IMPORTANT
Wheels, tires, and rims are dimensioned and selected
for each machine type so that maximal wheel loads
and speeds are not exceeded. That is why it is not per-
mitted to change tire dimension, tore make, tire type,
rim type, or rim brand without approval from
Cargotec.
Changing wheel:
–
Changing wheels, see Maintenance manual.
DANGER
When changing tyres, deflate first.
Deflate tyres by loosening and removing the valve.
DANGER
Rim damage makes wheel handling extremely
dangerous!
Let service personnel change tyres, they have the

competence and authority to handle tyres!

190 6 Inspection and maintenance – 6.2.10 Tyres and rims
Inflating tyres
–
Care of compressor for inflating tyres:

• An air filter with water separator should be installed in the line from
the compressor used for inflating tyres. The water filter minimises
the risk of corrosion on rims.
• Drain the water separator regularly.
DANGER
Never stand in front of a tyre when inflating! Do not
exceed prescribed air pressure, which is to be
checked at ambient temperature. When changing tyre
or rim version, another tyre pressure may apply, con-
tact Cargotec. The plate for tyre air pressure must be
replaced with a plate with the applicable tyre
pressure!
Extreme danger!
Always follow instructions for inflating tyres to avoid

serious accidents.
000384
1. Before inflating, make sure that the rim’s lock ring is in the correct
1 2 3 position.
NOTE
If the tyre has been completely deflated, the rim must be dis-
mantled and checked for damage. Let service personnel
change tyres as they have the competence and authorisation
0022002
to handle tyres!
1. Lock ring 2. Connect the compressor with a locking air-chuck to the nipple on
2. Rim edge the tyre.
3. Tapered rim 3. Move to the side and stay to the side of the tyre until inflating has
been completed.
4. Inflate the tyre to the prescribed pressure, see chapter 9 Specifi-
cations. When changing tyre or rim version, another tyre pressure
may apply, contact Cargotec.

6 Inspection and maintenance – 6.2.11 Checking accumulators 191
6.2.11 Checking accumulators

Accumulators, general
page
–
The function of the accumulators (position A) is to maintain even brake

pressure and also to maintain brake pressure, and thus braking action,
a short time after eventual loss of hydraulic pressure.
A The accumulators are precharged with nitrogen gas.

Instructions
Check sealing according to the following points if the warning lamp for
low brake pressure (position 33) lights up:
1. Start the engine and let it run until the accumulators are filled.
Warning lamp for low brake pressure (position 33) goes off.
2. Stop the engine and then turn the start key to position I.
3. Press down the brake pedal with long pumping brake strokes, with
a slight delay between each braking action.
4. It should be possible to brake at least eight times before the light
for low brake pressure lights up.
5. Start the engine, let the accumulators charge and repeat the test
a couple of times.
000385
A If it is not possible to brake eight times before the warning lamp for low
A. Accumulators for brake system brake pressure lights up, there is a defect in the accumulators. Contact
service as soon as possible for troubleshooting and suitable action.
WARNING
The machine’s hydraulic system includes accumula-
tors with high pressure.
Always be very careful when working with the hydrau-

lic system, and avoid standing close to hydraulic
components or hoses. Before working on the hydrau-
lic system, the accumulators must be drained (see
Maintenance manual).

192 6 Inspection and maintenance – 6.2.12 Battery and battery disconnector
6.2.12 Battery and battery disconnector

Battery and battery disconnector, general
page
–
WARNING
Short-circuiting of battery.
Risk of explosion! Fire hazard! Risk of personal

injury!
The battery’s terminals may not be connected to each

A 006463 other or to common ground (chassis).
A. Battery disconnector
CAUTION
Always turn off the electric power at the end of your
shift, when working on the electrical system and
when welding on the machine.
Danger!
Turn off the electric power with the battery

disconnector.
The electrical system operates with a system voltage of 24 VDC. The

voltage source consists of two series-connected 12 VDC batteries that
are charged by an alternator. The minus terminal is connected to the
frame.
The plus terminal is connected to a battery disconnector (position A).
The batteries are located inside of a cover behind the steps on the ma-
chine’s left-hand side.
Checking electrolyte level in battery
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Health hazard!
Use protective glasses and protective gloves when

working with the batteries. Immediately remove elec-
trolyte on bare skin. Wash with soap and plenty of wa-
ter. If electrolyte has splashed in eyes, rinse
immediately with plenty of water and contact a doctor
immediately.

6 Inspection and maintenance – 6.2.12 Battery and battery disconnector 193
Checking the electrolyte level is recommended. Fill as needed with

deionised water.
1. Turn off the machine’s system voltage with the battery disconnec-
tor (position A) and then open the cover.
2. Checking the electrolyte level is recommended. Fill as needed
with deionised water.
Electrolyte’s fluid surface should be 10 mm over cells.
Batteries contain substances hazardous to the environment and per-
sonal health. Therefore, discarded batteries must be handled accord-
ing to local/national regulations.
Starting with booster battery
WARNING
Handle batteries and connectors with care when
charging and during starts with booster batteries. Do
not mix up the battery terminals! Follow instructions
for starting with booster battery!
Risk of short-circuiting! Warning - generation of oxy-

hydrogen gas! Sparks and fire hazard! Oxy-hydrogen
gas is very explosive! Risk of explosion!
Batteries should always be provided with protective

caps over the terminals and connections. Connect
the positive (plus) terminals first. Then connect the
negative (minus) terminals to prevent sparks that may
ignite the hydrogen gas.
1. Turn off the machine’s system voltage with the battery disconnec-
tor (position A) and then open the cover.
2. Check that booster batteries are connected in series to system
voltage 24 VDC. Do not disconnect installation cables at the ma-
chine’s batteries (assumed to be discharged)!
3. Connect in the following order:
a. The red booster cable (+) to the discharged batteries’ plus
terminal.
b. The red booster cable (+) to the booster batteries’ plus terminal.
c. The black booster cable (–) to the booster batteries’ minus
terminal.
d. The black booster cable (-) to a point some distance from the
discharged batteries, e.g. at the minus cable’s connection to the
frame or directly to the engine block.
4. Try to start the engine and then run the engine at increased idling
speed for approx. 10 minutes to charge the batteries.
Do not move the connections during the start attempt – risk of
sparks. Do not lean over any of the batteries.

194 6 Inspection and maintenance – 6.2.13 Main fuses for electrical system
5. Turn off engine.

Remove the cables in reverse order as when installing. One cable
at a time! Batteries shall always be provided with caps over termi-
nals and connections.
6.2.13 Main fuses for electrical system

Main fuses for electrical system, general
page
–
CAUTION
C B
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and

ampere rating.
The machine’s electrical system has one position for main fuses and
two positions for boom and attachment fuses:
A. Main fuses in electronic box on frame, 4 fuses 50 A.
Cuts off all electric power.
A
B. Fuses at mounting of boom to frame (left side), 2 fuses 25 A.
Cuts off electric power to attachment.
C. Fuses at boom outer (left side), 2 fuses 25 A.
Cuts off electric power to attachment.
Changing main fuse/fuse
012784
When checking and changing main fuse/fuse:

A. Main fuse in electrical distribution box on frame
B. Fuse boom, fuse by inside boom mounting frame 1. Turn off the system voltage with the battery disconnector.
C. Fuse attachment, fuse by boom outer The engine shall be off.
2. Remove the plastic cap (position A).
3. Check and change fuses when needed.
Fuses are rated at 25 or 50 A.

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 195
6.2.14 Fuses for electrical system

Fuses for electrical system, general
page
–
The machine’s electrical system is divided into three electric power

circuits:
• Battery voltage, so-called 30-voltage
• Ignition voltage, so-called 15-voltage
• Control breaker voltage, so-called 15E-voltage
The fuses for the electrical system are located in the electronic box on
the side of the machine and in an electronic box in the cab.
D The electronic box is located behind the driver’s seat in the cab. There
are fuses for the control computers and equipment in the cab.
E
CAUTION
Never use fuses with too high ampere rating.
Risk of cable damage or cable fire!
Follow instructions on the fuse plate for fuse type and

ampere rating.
A
B
010939
C
Fuses on frame
A. 30-fuses (battery voltage), 58-1
B. 15-fuses (ignition voltage), 58-2
C. 15E-fuses (control breaker voltage),58-3
Fuses in cab
D. 15-fuses (ignition voltage) and 30-fuses (battery
voltage), 58-4
E. 15-fuses (ignition voltage), 58-5

196 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
A1 30A CAB
A48498.0100
B2
C3 15A ENGINE
F58-1 30 MAIN POWER

D4 10A ENGINE
E5 5A TRANSMISSION
F6 15A ENGINE, OPT
G7
H8
A1 25A KDU,FRONT (KALMAR DISTRIBUTION UNIT)
B2 5A ENGINE,ECC
F58-2 15 SUPPLY POWER
C3 25A KDU,REAR (KALMAR DISTRIBUTION UNIT) 10A KCU (KALMAR CAB UNIT)
D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT) 5A KCU, START UP (KALMAR CAB UNIT) X2044980 1
10A SERVICE
E5 5A TRANSMISSION
10A OPT CUSTOMER
F6
10A OPT RADIO
G7
25A OPT SEAT HEATER, TURNABLE SEAT
H8 5A ENGINE
15A OPT WORK LIGHT
15A OPT AIRCUSHIONED SEAT
A1 25A ATTACHMENT
B2 10A KDU,FRONT (KALMAR DISTRIBUTION UNIT) 25A KCU (KALMAR CAB UNIT)
F58-3 15E SUPPLY POWER
C3 10A KIT (KALMAR INFORMATION TERMINAL)
D4 10A KDU,OPT (KALMAR DISTRIBUTION UNIT) 15A ECC, FAN (ELECTRONIC CLIMATE CONTROL)
5A ECC, RECIRC (ELECTRONIC CLIMATE CONTROL)

E5
EMERGENCY
10A SERVICE
F6
5A OPT MAP READING LIGHT
G7
10A OPT CONVERTER 12V
014721
H8 5A FEEDBACK K3009-1 (K2)
10A OPT COMPRESSOR HORN
Fuse plate at electronic box for frame (left) and cab (right)
Table 6. Fuse holder 58-4 (cab)
Connection Fuse number / Size Functions
1 1 / 10A Control unit cab (KCU)
2 2 / 5A Control unit cab (KCU), start-up
3 3 / 10A Service
4 4/-
Customer-specific equipment
5 5 / 10A
Radio
6 6 / 25A
Seat heat
7 7 / 10A
Work light boom
8 8 / 15A
Air suspension, driver’s seat

6 Inspection and maintenance – 6.2.14 Fuses for electrical system 197
Table 7. Fuse holder 58-5 (cab)
1 1 / 25A Control unit cab (KCU)
2 2 / 10A Control unit KIT
3 3 / 15A Air conditioning, fan
4 4 / 5A Air conditioning, recirculation
5 5 / 10A Service
6 6 / 5A
Lighting, writing table
7 7 / 10A
Voltage converter 12 VDC
8 8 / 10A
Loud horn
Table 8. Fuse holder 58-1 (30-voltage)
1 1 / 30A Cab
2 2/- -
3 3 / 15A Engine
4 4 / 10A Engine
5 5 / 5A Transmission
6 6/- Engine
7 7/- -
8 8/- -
Table 9. Fuse holder 58-2 (15-voltage)
1 1 / 25A Control unit frame (KDU) front
2 2 / 5A Engine, air conditioning
3 3 / 25A Control unit frame (KDU) rear
4 4 / 10A Control unit frame (KDU) option
5 5 / 5A Transmission
6 6/- -
7 7/- -
8 8 / 5A Engine

198 6 Inspection and maintenance – 6.2.14 Fuses for electrical system
Table 10. Fuse holder 58-3 (15E-voltage)
1 1 / 25A Attachment
2 2 / 10A Control unit frame (KDU) front
3 3/- -
4 4 / 10A Control unit frame (KDU) option
5 5/- -
6 6/- -
7 7/- -
8 8 / 5A Feedback relay K3009-1 (K2)
Instructions
When checking and changing fuses:
1. Turn off the system voltage with the battery disconnector.
The engine shall be off.
2. Remove the cover from the electronic box.
3. Check and change fuses when needed.
The fuse plate gives information about each fuse.

6 Inspection and maintenance – 6.2.15 Lighting 199
6.2.15 Lighting
Lighting, general
page
–
It’s important to use the right type of light bulb for respective lighting
point, see section 9 Specifications.
Light bulbs can be changed for the following:
• Interior lighting
• Rear light, red
• Brake light
• Indicator light for travel direction
• Position light
• Headlights (for high and low beams)
• Reversing light, white
• Working light, glowing light
Working lights, Xenon

• Revolving beacon

200 6 Inspection and maintenance – 6.3 Service
6.3 Service
General
page
–
It’s very important that inspections and service are performed at the
recommended intervals.
Service is performed by Cargotec, or by service technicians author-
ised by Cargotec.
CAUTION
Service interval must be followed.
This is to maintain the machine’s safety as well as to

meet warranty and service agreements!
Use spare parts and fluids approved by Cargotec to

fulfil warranty terms.
Service intervals and actions are described in the maintenance

manual.
CAUTION
Undo the connectors from the control units.
Risk of damage to the control units!
When welding on the machine, all control units shall

be disconnected to prevent damage.

6 Inspection and maintenance – 6.3 Service 201
WARNING
For safety reasons, the following spare parts may
only be replaced with genuine spare parts:
• Brake valve
• Drive axle
• Valve for mini-wheel/joystick steering
• Steering valve (Orbitrol)
• Steering valve incl. priority valve
• Steering axle
• Steering cylinder
• Rim
• Boom nose extension
• Lift cylinder
• Valve block lift
• Extension cylinder
• Valve block extension
• Rotation motor unit
• Tilt cylinder
• Twistlock, lift shoe
• Control breaker (for hydraulic function)
• Emergency stop
• Accumulator
• Main valve load handling
• Accumulator charging valve
• All control units

202 6 Inspection and maintenance – 6.3 Service

7 Transporting the machine 203
7 Transporting the machine
7 Transporting the
mm mm mm mm mm mm
machine
Safety
page
–
DANGER
The machine must be adequately secured during
transport! The machine is heavy and can cause exten-
sive damage in case of a fall and similar.

ty damage!
Follow the instructions in order to secure the machine

during transport.
WARNING
Operator doors must always be closed during
transport.
Danger!
Always close operator doors during transport.
WARNING
The cab has the sliding cab feature, manual or hy-
draulic ( ). The cab shall ALWAYS be secured and
locked when transporting.
Risk that unsecured cab moves, which results in

great danger!
For manual sliding cab, always make sure that the cab
locks on both sides are locked in their rear position
before transport, and that the locks are secured with
the lock pins.
For hydraulic longitudinal displacement, the cab may

be positioned as desired (locking is automatic) when
stationary.

204 7 Transporting the machine – 7.1 Towing
7.1 Towing
General
page
–
DANGER
The machine cannot be operated or braked if the hy-
draulic pressure is lost, e.g., if the engine is off.
Rolling machine! Extreme danger!
If possible, tow with maintained hydraulic pressure. If

it’s not possible to tow with the engine running, a tow
bar must be used! Only tow for short distances!
CAUTION
Do not try to start the machine by towing.
Serious damage to engine and power transmission!
Start the engine according to instructions in the oper-

ator’s manual.
Before taking actions and after finished towing, the parking brake must
be applied and the wheels blocked to prevent the machine from start-
ing to roll.
Extreme care must be observed during towing work to avoid personal
injuries.
When towing, keep in mind:
• The towing vehicle should be heavier than the vehicle in tow.
• If possible when towing, the engine should be running in order for
brakes and steering to function.
When the engine is off, there’s no hydraulic pressure to the steer-
ing function and thus the machine’s steering function is severely
limited. Also, transmission lubrication is insufficient.
• The brakes function as long as there’s pressure in the accumula-
tor, then the service brake stops functioning and the parking brake
is applied automatically. If it’s necessary to move/tow the machine
after that, the parking brake must be released mechanically, see
section 7.1.1 Mechanical release of parking brake.
• Only tow for very short distances.
• If it’s necessary to tow the machine, the propeller shaft must be
disconnected from the transmission.

7 Transporting the machine – 7.1.1 Mechanical release of parking brake 205
7.1.1 Mechanical release of parking brake

Description
page
–
The parking brake is applied automatically by a forceful spring in the

brake cylinder if the pressure in the hydraulic accumulator should drop
below a certain level.
If the machine has to be moved (towed) without sufficient pressure in
the hydraulic accumulator, the parking brake must be released me-
chanically (manually).
DANGER
Before starting to work with the parking brake, make
sure that the machine cannot move when the braking
action is released.
Rolling machine! Extreme danger!
Block the wheels to avoid unwanted rolling of the

machine.
CAUTION
The parking brake has high spring force. If the brakes
are opened incorrectly, parts may detach and fly off
with great force.
Follow the instructions.
The parking brake is a disc brake on the drive axle’s input shaft.
A B C
1. Remove protective cover from caliper (position A).
2. Note the nut’s position on the bolt and remove the split pin that se-
cures the nut.
3. Screw in the nut, this compresses the brake spring. Screw until
the brake pads release from the brake disc.
4. Restore the parking brake function by screwing out the nut to the
same position acc. to item 2. Install new split pin.
5. Refit protective cover on the caliper.
NOTE
000835
If the parking brake has been released mechanically, the parking

A. Protective cover brake must always be restored in order to give the machine park-
B. Brake disc for parking brake ing brake function.
C. Propeller shaft

206 7 Transporting the machine – 7.2 Lifting and transporting the machine
7.2 Lifting and transporting the

machine
General
page
–
When lifting and transporting the machine, follow the governing safety
regulations.
DANGER
High demands are made of the lift and transport
equipment, e.g., lifting chains, hooks, etc.
Extreme danger!
Check the equipment and its capacity, lifting slings

on the machine as well as lashing points on the trans-
port and machine.
DANGER
Overload of load equipment.
Extreme danger!
Lifting equipment should be dimensioned for the

load. Never walk under a suspended load.
The following actions are recommended when the machine is to be

transported:
• Turn off the main electric power with the battery disconnector.
• Apply parking brake.
• Remove any fragile equipment, e.g. rear view mirrors.
Transport of machine on public roads takes place in accordance with
the following:
1. Lift of attachment. see Removing the top lift attachment page 207.
Lift of boom. see Removing the boom page 209.
NOTE
Only needed if transport takes place on public roads.
2. Secure the machine for transport on, e.g., a truck. Note the ma-
chine’s weight, see machine plate.
Place the machine, boom and attachment on the transport. See
Lashing down for transport page 212.
3. Lift boom: see Installing the boom page 215.
Lift attachment. see Installing the top lift attachment page 216.

7 Transporting the machine – 7.2.1 Lifting machine 207
7.2.1 Lifting machine

Instructions
page
–
The machine shall be lifted as follows:

1. Lay two lifting slings in both front lifting eyes on the frame.
2. Lay two lifting slings in both rear lifting eyes on the frame (at the
boom mounting).
3. The lifting device must be adapted so that the lifting point runs
through the machine’s centre of gravity.
001848
7.2.2 Transporting the machine

Removing the top lift attachment
page
–
WARNING
Pressurised oil system.
Always depressurise the hydraulic system before

starting to work in the hydraulic system.
1 Park the machine with the boom fully retracted in its lowest posi-
tion and the attachment in right-hand position.
2 Switch off the engine and open the relief valve for the attachment.
Relief valve attachment opens a connection between the attach-
ment’s pressure feed and tank. This is used to drain the pressure
in the hoses for the attachment before working on the hydraulic
system. The relief valve is located at the trailing edge of the lift
beam in front of the transmission.
002269
3 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
Relief valve for attachment
4 Turn the start key to position 0 and turn off the main electric pow-
er with the battery disconnector.
5 Place a collection container under the valve block on the boom
nose to collect any oil spills.

208 7 Transporting the machine – 7.2.2 Transporting the machine
6 Mark up and disconnect the attachment’s hydraulic connections

from the damping block.
NOTE
Plug all connections to protect the hydraulic system from
impurities.
7 Disconnect the cable harness for the attachment from control unit
attachment.
Remove the cable harness’ clamping from the boom.
NOTE
Plug all contacts to protect them from dirt and moisture.
8 Disconnect the tilt cylinders from the attachment.
Remove the tilt cylinders’ shafts and turn aside the tilt cylinders.
If necessary, use a puller to press out the shaft. Refit the shafts
in the tilt cylinder.
9 Remove the collection container, handle the waste oil as environ-
mentally hazardous waste.
10 Connect lifting equipment securely to the attachment’s lifting
eyes
11 Adjust the lifting equipment to take the weight/stress off the shafts
on the rotation bar.
12 Remove the rotation bar’s shafts.
Remove the lock bolts and pull out the shaft. If necessary, use
two bolts in the threaded holes to pull out the shaft.
13 Lift aside the attachment. Place it on wooden blocks or similar so
that the twistlocks are not damaged.
14 Refit the rotation bar’s shafts in the rotation bar.

7 Transporting the machine – 7.2.2 Transporting the machine 209
Removing the boom

–
11 1 2 10
12
003690
9 8 7 8 6 5 4 3
1. Outer boom 7. Lift cylinder
2. Inner boom 8. Mounting lift cylinder
3. Tilt cylinder right-hand side 9. Rear boom mounting
4. Mounting attachment 10. Front lifting eyes
5. Tilt cylinder left-hand side 11. Rear lifting eyes
6. Extension cylinder 12. Valve block boom nose
DANGER
A lift cylinder weighs approx. 2 tonnes.
Extreme danger!
Use wooden blocks as protection between cab and lift

cylinder when the lift cylinder is lowered or lifted. Se-
cure the lift cylinders with tensioning straps in be-
tween them.

WARNING
The boom may move when the shafts are removed.
Make sure that the pins are relieved of stress. Stand

to the side of the boom mounting so that the mount-
ing protects in case of a movement.
CAUTION
The boom may drop.
Be certain to compensate for the lift cylinder’s sup-

port of the boom by lifting the boom’s leading edge
with the lifting equipment.
CAUTION
Short-circuiting. Use contacts with blind plugs at both
ends to isolate and protect all connectors that are
unplugged.
Product damage, moisture and dirt.
The instruction requires that the top lift attachment has been removed,
see Removing the top lift attachment page 207.
1 Place a collection container under the hydraulic oil connections
at the boom’s rear mounting to collect any spills.
2 Clean, mark up, disconnect and plug the hydraulic hoses at the
boom’s rear mounting. Detach the hoses from the hose bracket.
Right-hand side, hydraulic hoses for boom.
Left-hand side, hydraulic hoses for attachment.
NOTE
Plug all connections to protect the hydraulic system from
impurities.

3 Remove the collection container, treat spills as environmentally

hazardous waste.
4 Mark up and disconnect the cable harness from the boom at the
rear mounting.
NOTE
Plug all contacts to protect them from dirt and moisture.
5 Slide the cab completely forward.
6 If the machine is equipped with position sensor for boom angle,
remove the sensors’ bracket and the sensor so that is not dam-
aged when the boom is placed on the ground.
If the machine is equipped with analogue sensor, leave the sen-
sor on the boom but fixate the sensor’s arm with a cable tie.
7 Connect lifting equipment securely at the front of the boom. Lift
the front of the boom so that the lift cylinders are relieved.
8 Connect lifting equipment to the lift cylinder.
9 Disconnect the lift cylinders from the boom.
Angle sensor Remove the lock bolt and the shaft. If necessary, use a puller to
pull out the shaft.
10 Carefully lower each lift cylinder so that it rests against the edge
on the lower mounting.
Use wooden blocks as protection between cab and lift cylinder
when the lift cylinder is lowered or lifted. Secure the lift cylinders
with tensioning straps in between them.
11 Refit the shaft in the boom’s bearing.
12 Connect the lifting equipment securely in the lifting eyes in the
boom’s trailing edge. Lift slightly to relieve the boom’s rear
bearings.
13 Remove the shafts for the boom mounting.
14 Lift away the boom, lower the front part and place it on a secure
surface, e.g. wooden blocks.

15 Depressurise the tilt cylinders.

Loosen the hydraulic hoses’ connections at the valve block on the
boom nose.
Place a collection container under the valve block to collect any
oil spills.
NOTE
The tilt cylinders must be drained to allow the rear part of the
boom to be laid down.
16 Lower the rear part of the boom and place it on a secure surface,
e.g. wooden blocks.
17 Tighten the tilt cylinders’ hydraulic hoses at the valve block on the
boom nose.
18 Remove the collection containers, handle the waste oil as envi-
ronmentally hazardous waste.
Valve block boom nose
Lashing down for transport
–
The instruction requires that the top lift attachment and boom have
been removed, see Removing the top lift attachment page 207 and
Removing the boom page 209.
When transporting the machine, boom and attachment must be trans-
ported separately. The machine must be transported on a trailer that
is wide enough to support the drive axle’s inner wheel.
1. Reverse the machine up on the trailer.
2. Apply parking brake.
3. Turn off the main electric power with the battery disconnector.
4. Secure the front part of the machine adequately in the front of the
frame and in the intended attachment points on the trailer.
Cross the chains when securing for optimal stability.
Lashing down machine, front

5. Secure the rear part of the machine adequately in the rear of the
frame and in the intended attachment points on the trailer.
Lashing down machine, rear

6. Fold in the rear-view mirrors and remove protruding parts, such as
the rotating beacon, to prevent damage during transport.
7. Place the boom’s rear part on anchored pallets or similar.
Secure the boom’s rear part adequately in the boom’s lifting eyes
and in the intended attachment points on the trailer.
Lashing down boom, rear

8. Secure the boom’s front part adequately in the boom’s lifting eyes
and in the intended attachment points on the trailer.
Lashing down boom, front

9. Place the attachment on wooden blocks or similar to protect the
twistlocks.
Secure both sides of the attachment adequately in the attachment
lifting eyes and in the intended attachment points on the trailer.
Lashing down of attachment

Installing the boom

–
WARNING
Pressurised oil system.
Always depressurise the hydraulic system before

starting to work in the hydraulic system!
The instruction requires that top lift attachment and boom are not as-
sembled, i.e. are separate.
1 Place the cab in the front position.
2 Switch off the engine and open the relief valve for the attachment.
3 Turn the start key to position I and activate the hydraulic functions
to depressurise the hydraulic system.
4 Turn the start key to position 0 and turn off the main electric pow-
er with the battery disconnector.
5 Connect lifting equipment at the leading edge and trailing edge of
the boom.
6 Lift the boom into place over the machine.
7 Adjust the boom’s position so that the holes for the boom’s bear-
ings in the boom and frame are lined up.
NOTE
If sensor boom angle is still on the boom, fit the sensor’s arm
in the lock screw without turning the sensor’s arm.
8 Fit the rear shafts for the boom’s bearing.
9 Disconnect the lifting equipment from the boom’s trailing edge.
10 Lower the boom’s leading edge so that it is horizontal.
002269
11 Connect lifting equipment to one of the lift cylinders.

Relief valve for attachment 12 Align the lift cylinder’s upper mounting in the boom.
Lift the lift cylinder into place, if necessary adjust the angle of the
boom.
13 Fit the lift cylinder’s shaft.
14 Lower the boom and disconnect the lifting equipment from the
boom.
15 Place a collection container under the hydraulic oil connections
at the boom’s rear mounting to collect any spills.
16 Connect the boom’s hydraulic hoses to the machine.
NOTE
Check that the O-rings are intact, clean and in the correct
position.

17 Connect the cable harness to the boom.

18 If the machine is equipped with position sensor for boom angle,
fit the bracket and sensor boom angle.
19 Grease the boom’s rear bearings with lubricating grease EP2.
20 Check that the tilt cylinders’ hoses are securely tightened.
21 Remove the collection containers, handle the waste oil as envi-
ronmentally hazardous waste.
Installing the top lift attachment

–
CAUTION
Do not overfill! The hydraulic oil level is checked with
the boom completely lowered and retracted.
Leakage and environmental damage
The instruction requires that the boom is mounted on the machine, see
Installing the boom page 215. The boom must be in lowered position.
1 Remove the rotation bar’s shafts from the rotation bar.
2 Clean and grease the bearing surfaces for mounting and tilt cyl-
inders on the attachment with lubricating grease EP2.
3 Connect lifting equipment securely to the attachment’s lifting
eyes.
4 Lift the attachment into place. Align the attachment so that the
holes for the shafts in the boom line up with the holes for the
shafts in the rotation bar.
5 Clean and grease the attachment’s mounting pins with lubricating
grease EP2 before installing.
6 Fit the attachment’s mounting pins and fit the lock bolts.
7 Clean and apply aluminium paste, e.g., Loctite 8150, on the tilt
cylinders’ link bearings and shafts.
8 Connect the tilt cylinders to the attachment.
Align the tilt cylinder and press in the pin. Fit the lock bolt. If nec-
essary, loosen the hydraulic connections on the tilt cylinder to en-
able adjustment of the tilt cylinder’s length.

9 Remove the plugs and connect the attachment’s hydraulic hoses

to the valve block on the boom nose.
NOTE
Check that the O-rings are intact, clean and in the correct
position.
10 Connect the cable harness to control unit attachment.
11 Grease the attachment’s bearing with lubricating grease EP2.
12 Turn on the main electric power with the battery disconnector.
13 Start the engine.
14 Check that the hydraulic connections are sealed tightly.
15 Check the attachment’s functions.
16 Check the hydraulic oil level with the lift cylinders completely
down and the extension cylinder completely in. The oil level
should be at the top of the level glass. Top up if necessary.

218 7 Transporting the machine – 7.3 Service position
7.3 Service position

General
page
–
Service position is used for service, maintenance and other situations

when the machine needs to be secured.
Service position entails:
• The machine is parked, i.e. parking brake applied.
• Boom fully retracted and lowered to horizontal position.
• Engine off.
• Main electric power turned off with the battery disconnector.
003695
Machine with fully retracted and lowered boom
7.4 Long-term storage

General
page
–
For long-term storage of the machine, contact Cargotec.

8 Environment and standards 219
8 Environment and standards
8 Environment and
mm mm mm mm mm mm
standards
General
page
–
Ever-increasing industrialisation of our world is having a significant im-

pact on our global environment. Nature, animals and man are subject-
ed daily to risks in connection with various forms of chemical handling.
There are still no environmentally safe chemicals, such as oils and
coolants, available on the market. Therefore, all who handle, perform
service on or repair machines must use the tools, assisting devices
and methods necessary to protect the environment in an environmen-
tally sound manner.
By following the simple rules below, you will contribute to protecting
our environment.
Recycling
Conscientious recycling of the machine is the starting point for the life
cycle to come full circle, and for being able to recycle and make use of
material in new products. According to calculations by Cargotec, more
than 90% of the machine weight is recyclable.
Environmentally hazardous waste

Components such as batteries, oils, and various chemicals and other
items that may constitute environmentally hazardous waste must be
handled and taken care of in an environmentally safe and sound
manner.
Discarded batteries contain substances hazardous to personal health
and the environment. Therefore, handle batteries in an environmental-
ly safe manner and according to national regulations.
Oils and fluids

Oils freely discharged cause environmental damage and can also be
a fire hazard. Therefore, when emptying and draining oils or fuel, take
appropriate action to prevent unnecessary spills.
Waste oils and fluids should always be taken care of by an authorised
disposal company.
Pay close attention to oil leaks and other fluid leaks! Take immediate
action to seal the leaks.
Air conditioning
The refrigerant in the air conditioning for the cab adds to the "green-
house effect" if released into the open air. Special training is required
for all service work on the air conditioning. Many countries also require
certification by a governing authority for such work. When scrapping
an air conditioning unit, the refrigerant shall be taken care of by a cer-
tified company.

220 8 Environment and standards
Working in a contaminated area

The machine shall be equipped for work in contaminated areas (envi-
ronmentally polluted or health-hazardous area) before work is started.
Also, there are special local rules for such handling and when servic-
ing such a machine.
Declarations
The machine does not contain asbestos.
The machine contains lead in batteries and cable harnesses. In cer-
tain models, cast lead is used in counterweights.
If the machine is equipped with air conditioning, refrigerant of type
R134a is used, in an amount totalling between 1-3 kg.
Standards
–
Noise, vibration, stability and visibility, etc.

This machine fulfils applicable standards in accordance with EN1459
"Safety of industrial trucks - Self-propelled variable reach trucks".
CE-marking
Machines for the EU/EEA market are CE-marked. This means that
upon delivery the machine fulfils the applicable "Essential Health and
Safety Requirements" specified in the EU Machine Directive,
2006/42/EC, as well as other EU directives relevant to this machine
type. For more information, see section 2.2 CE-marking.
ANSI/ ITSDF marking

Versions of this machine for North America are ANSI/ITSDF-marked.
This means that, when delivered, the machine fulfils the basic safety
requirements specified in ANSI/ITSDF B56.1. For more information,
see section 2.3 ANSI/ITSDF-marking.
EMC, electromagnetic interference

The EU’s EMC directive regarding "Electromagnetic compatibility",
2004/108/EC, gives a general description of the standards that may be
required of a machine from a safety aspect, where the limit values
have been established in international standards. A machine or device
that meets these standards should be CE-marked.
Cargotec machines are especially tested with regards to electromag-
netic interference in accordance with harmonised standard EN12895.
The machine’s CE-marking and declaration of conformity also cover
the EMC directive. If other electronic equipment is installed on the ma-
chine, it must be CE-marked and tested on the machine with regards
to electromagnetic interference. It must also be approved by Cargotec.

8 Environment and standards 221
Exhaust emissions
Machines for the EU/EEA market fulfil EU's Exhaust directive
97/68/EC and 2004/26/EC, which means that the engine’s exhaust
emissions have been limited according to the requirements.
Machines for the North American market fulfil EPA's and CARB's ex-
haust regulations, which means that engine exhaust emissions have
been limited according to the requirements.
Vibration standard
Vibrations emitted by the machine are measured according to harmo-
nised standard EN 13059, where the level of vibrations varies depend-
ing on with which type of tyres and operator’s seat the machine is
equipped. See section 9 Specifications.

222 8 Environment and standards

9 Specifications 223
9 Specifications
9 Specifications
mm mm mm mm mm mm
Technical data
page
–
Machine weights and dimensions vary depending on how the machine

is equipped and are shown in detail in the product specification and
spec sheet for the machine in question.
1 Engine Volvo TAD1250VE Volvo TWD1240VE Cummins QSM11
Power acc. to ISO 3046 (net power) 247 kW at 1900 rpm 256 kW at 2000 rpm 261 kW at 2000 rpm
Torque ISO 3046 1760 Nm at 1400 rpm 1751 Nm at 1200 rpm 1830 Nm at 1100-1400
rpm
Number of cylinders 6 cylinders 6 cylinders 6 cylinders
Alternator, output 2240 W (28 V / 80 A) 2240 W (28 V / 80 A) 2800 W (28 V / 100 A)
System voltage, voltage–capacity 24 V (2x12 V / 140 Ah) 24 V (2x12 V / 140 Ah) 24 V (2x12 V / 140 Ah)
2. Transmission Dana-Spicer Off Highway TE32 ZF 5WG261
No. of gears, forward – reverse 4–4 5–3
3. Power transmission Meritor Kessler
Drive axle, type Meritor, PRC7534W4H Kessler D102
4. Brakes
Footbrake system – wheel affected Wet Disc Brake – drive wheel
Parking brake system – wheel affected Spring brake – drive wheels
5. Steering
Steering system Hydraulic servo
6. Wheels DRF420 DRF400/450 DRF450. x
Dimension, front and rear 18.00x25/36 18.00x25/40 18.00x33/36
Tyre pressure, also see pressure plate 1.0 MPa
Tyre type, front and rear Air inflated. Spare and replacement tyres must be from a manufacturer approved
by Cargotec.

224 9 Specifications
9. Cab Spirit Delta with Volvo Spirit Delta with Volvo Spirit Delta with
TAD1250VE TWD1240VE Cummins QSM11
Equivalent sound pressure level in cab LpAZ 74 dB(A) LpAZ 73 dB(A) LpAZ 73 dB(A)
according to EN12053 with measure-
ment uncertainty R =2.5 dB. Meas-
urement value with standard engine.
Whole-body vibrations according to 0,5 m/s2

EN13059 with measurement uncer-
tainty k=0.3 x measured value.
Specifications oil, lubricants and

–
fluids
Any deviation from this table must be approved in writing by Cargotec.
1.2 Engine, fuel system

Fuel tank, volume 550 l
Fuel quality Diesel, according to EN590
1.7 Engine, cooling system Volvo TAD1250VE Volvo TWD1240VE Cummins QSM11
Coolant volume 40 l 68 l 40 l
Coolant filling point Volvo Penta Coolant VCS, ready-mixed ES Compleat, Premix
CAUTION!
Risk of engine damage if different types of coolant are mixed.
When changing and topping up coolant, the same type of coolant must be
used as was used before. See Spare parts catalogue for correct part number.
Oil volume 35 l 35 l 34 l
Oil type, quality See Recommended oils and lubricants page 226.
2.6 Transmission, lubrication Dana TE32 ZF 5WG261

system
Oil volume 80 l 58 l
3.3 Power transmission, drive axle Meritor, PRC7534W4H Kessler D102
Differential, oil volume 50 l 65 l
Hub reduction, oil volume 2x10 l 2x12 l

4 Brakes
Oil tank brake system, volume 140 l
7 Load handling
Planetary gear hydraulic motor, oil volume 1.6 l
Disc brake hydraulic motor, oil volume 0.6 l
9 Frame, body, cab and accessories

Refrigerant, volume 2000 g
Refrigerant air conditioning R134a
Lubricant air conditioning Zexel PAG-oil
Washer fluid, volume 5l
10 Common hydraulics
Hydraulic oil tank, volume 600 l
Hydraulic oil system, volume 940 l (total, incl. tank)

Recommended oils and lubricants

–
The service intervals indicated by Cargotec in the maintenance man-

ual only apply if oils are selected in accordance with the table below.
The table indicates recommended viscosity for different oil types, and
grades, depending on the ambient temperature.
Any deviation from this table must be approved in writing by Cargotec,
and may mean changed service intervals.
°C -40 -30 -20 -10 0 +10 +20 +30 +40

Oil type, quality °F -40 -22 -4 +14 +32 +50 +68 +86 104
1.8 Engine, lubrication system
Volvo TWD1240VE: VDS-2 / ACEA E5 SAE 15W40
(Note 1) SAE 5W30 (motor oil)
Volvo TAD1250VE: VDS-3 (Note 2)
Cummins QSM11: API CH-4 / ACEA E5
2.6 Transmission, lubrication system
Dana: DEXRON III (trademark)
ATF Dexron III
ZF:
API: CD/CE/CF-4/CF/CG-4/ SAE 10W, 10W/30, 10W/40
CH-4/CI-4/SF/SG/SH/SJ/SL
SAE 15W/30, 15W/40
ACEA: Categories A, B, E
SAE 20W/20, 20W/40
SAE 30
3.3 Power transmission, drive axle

API GL-5 SAE 80W140
SAE 75W90
4 Brakes (UTTO-oil, Note 3)

GM Allison C-4 SAE 5W30 (transmission oil)
John Deere J20 C, D
Caterpillar TO-4
7 Load handling
Oil planetary gear hydraulic motor, hypoid oil SAE 80W140
API GL-5 SAE 75W90
Disc brake hydraulic motor, See 10 Common
hydraulics below
10 Common hydraulics
DIN 51524 Part 3 HVLP ISO VG 68
ISO VG 46 HV
ISO VG 32

NOTE
Oil filters shall always be changed in connection with oil change.
Change interval for engine oil requires that the sulphur content in
the fuel does not exceed 0.5%.
Note 1: Lubrication oil must meet both requirements. API CH-4 or
CI-4 are approved for markets outside Europe (instead of ACEA E5).
Note 2: The same oil as for Volvo TWD1240VE may be used on the
condition that the change interval is reduced to 400 hours.
Note 3: The oil in the brake system has to meet one of the quality
requirements.
ACEA = Association des Constructeurs Européenne d’Automobiles
API = American Petroleum Institute
VDS = Volvo Drain Specification
Lubricating grease
Use a universal grease type EP in accordance with NLGI Grade 2
(EP2) for all lubrication points except for slide plates lifting equipment
and slide plates.
For lifting equipment use a universal grease type EP in accordance
with NLGI Grade 2 (EP2) with 3.5% molybdenum disulphide mixture.
Use a Cargotec approved lubricant for the slide plates. Ordered from
the Cargotec spare parts department. 0.65 kg cartridge for grease
gun, part no. 923110.0360, and 5 kg can, part no. 923595.0003
Contact grease
Use electrical contact grease part. no. 923836.0552.
Sealant silicone
Use silicone part. no. 923107.0308.
Silicone adhesive
Use silicone adhesive part. no. 923854.0100.
Coolant
Use ready-mixed recommended coolant. Choose the mixture of cool-
ant that is adapted for the right temperature.
CAUTION
Risk of engine damage if different types of coolant are

mixed.
When changing and topping up coolant, the same

type of coolant must be used as was used before.

Specifications light bulbs

–
Lamp Output (W) Socket

Check lamps 1.2 W2x4.6d
Interior lighting 10 S8.5
Tail lights 5 BA15s
Brake light 21 BA15s
Direction indicators 21 BA15s
Tail lights, brake lights & direction indi- - Replaced complete

cators LED
Position lamps 5 W2.1x9.5d
- Replaced complete
Position lamps LED
Headlights, (with high and low beam) 75/70 P43t-38(H4)
Back-up light 70 PK22s(H3)
Working light, glowing light 70 PK22s(H3)
35 D1S Xenon tubes. Cartridge and ballast

Work lights, Xenon
replaced complete.
Unit explanations
–
Unit Abbreviation
Newton metre Nm
Kgf/m kpm
Kilo pascal kPa
Mega pascal MPa
Kilowatt kW
Kilojoule kJ
British thermal unit Btu
Calorie ca
Inch in
Feet ft
Yard yd
Mile mile
Centimetre cm
Metre m
Kilometre km

Conversion SI-units
–
SI-unit Recalculation Non-SI Recalculation SI

factor factor
Torque
Nm x 10.2 = kg·cm x 0.8664 = lb·in
Nm x 0.74 = lbf·ft x 1.36 = Nm
Nm x 0.102 = kg·m x 7.22 = lb·ft
Pressure (Pa = N/m2)
kPa x 4.0 = in.H2O x 0.249 = kPa
kPa x 0.30 = in.Hg x 3.38 = kPa
kPa x 0.145 = psi x 6.89 = kPa
bar x 14.5 = psi x 0.069 = bar
kp /cm2 x 14.22 = psi x 0.070 = kp/cm2
N/mm2 x 145.04 = psi x 0.069 = bar
MPa x 145 = psi x 0.00689 = MPa
Power (W = J/s)
kW x 1.36 = hp (cv) x 0.736 = kW
kW x 1.34 = bhp x 0.746 = kW
kW x 0.948 = Btu/s x 1.055 = kW
W x 0.74 = ft·lb/s x 1.36 =W
Energy (J = Nm)
kJ x 0.948 = Btu x 1.055 = kJ
J x 0.239 = calorie x 4.19 =J
Speed and acceleration
m/s2 x 3.28 = ft/s2 x 0.305 = m/s2
m/s x 3.28 = ft/s x 0.305 = m/s
km/h x 0.62 = mph x 1.61 = km/h
Horsepower/torque
Bhp x 5252 rpm = TQ (lb·ft) TQ x rpm 5252 = bhp
Temperature
ºC = (ºF – 32)/1.8 ºF = (ºC x 1.8) + 32
Flow factor
l / min (dm3/min) x 0.264 = US gal / min x 3.785 = litre/min

Conversion table length

–
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1 mm = 0.1 cm – 1 mm = 0.001 mm
Conversion table area

–
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 - 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 - 1000000 1 10000 1076400 1195800 -
a 0.01 100 0.0001 1 1076.4 119.58 -
ft2 - 0.092903 - 0.000929 1 0.1111 144.000
yd2 - 0.83613 - 0.008361 9 1 1296.00
in2 6.4516 0.000645 - - 0.006943 0.000771 1
1 ha = 100 a – 1 mile2 = 259 ha = 2.59 km2

Conversion table volume

–
Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = ml 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
dm3 (l) 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1 gal (US) = 3785.41 cm3 = 231 in3 = 0.83267 gal (UK)
Conversion table weight

–
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 1 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne (metric) = 1.1023 ton (US) = 0.9842 ton (UK)
Conversion table pressure

–
Unit kp/cm2 bar Pa = N/m2 kPa lbf/in2 lbf/ft2
kp/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa = N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kg/cm2 = 735.56 Dry (mmHg) = 0.96784 atm


10 Terminology 233
10 Terminology
10 Terminology
mm mm mm mm mm mm
Explanations
page
–
Term Description
Accumulator Reservoir that stores (accumulates) pressure for, i.e. hydraulic functions.
Anti-corrosion compound Prevents oxidation, in simple terms, rustproofing.
Attachment Part of the machine that grips the load when lifting.
Bar Unit to express pressure.
Battery disconnector Cuts off power supply from battery.
Boom Lifting member moveable vertically and in-out. Bracket for attachment.
Bottom lift attachment "Lifting legs" that can be raised/lowered for handling loads. Grabs load from below.
Buzzer Acoustic alarm to catch the operator’s attention.
Control valve Valves that can be used to control something, for example, to release pressure and thus
lower a boom or a fork. See also control valve.
Daily inspection Actions that should be performed daily to ensure the machine’s functionality.
Decitonne Tenth of a tonne, measure of machine’s lift capacity.
Display "Window" showing digital information, i.e. on steering wheel panel in cab.
Drive axle Driving axle that receives the torque from the drivetrain.
Drivetrain Parts in the machine involved in power transmission; engine, torque converter, transmis-
sion, propeller shaft and drive axle with differential and hub reduction.
Dust reservoir The air filter collects the coarsest particles in a dust reservoir, which is emptied automat-
ically during operation.
ECC Electric Climate Control. Climate control unit with thermostat-controlled cooling, dehumid-
ification and heating.
EHC Electric Heat Control. Heater unit with thermostat-controlled heating.
Electrolyte level Fluid level in battery cells.
Environmental waste Used oils, filters, etc., must be handled according to governing national laws and
regulations.
Expansion tank Tank for coolant.
Fixed displacement Non-adjustable volume (capacity) in a pump.
FMI Fault Message Identifier.
Hanging load Lifted load.
Hub reduction Type of final drive (often next to drive wheel) that reduces rpm and increases torque from
the drivetrain.
Hydraulic oil Oil for hydraulic system. See specifications in operator’s manual.
Hydraulic oil pump Pump in hydraulic system.
Hydraulic system System that uses oil pressure to transfer power to different functions.
Indicator Manual "sensor", for example, shows that a filter is clogged and needs to be changed.
LC Load centre

234 10 Terminology
Term Description
Levelling Attachment is tilted, for example if load stands on uneven ground.
Lift capacity Indicates machine’s maximum lift capacity.
Lifting point Attaching point for lift device when lifting an object.
Low-emission engine Engine with low emissions of hazardous substances. Manufactured according to speci-
fied and governing regulations.
Machine model Machine type. Indicated, for example: DRF 400-450. See also type designation.
Main fuse Located by the battery. Cuts off power to all machine systems.
Maintenance Periodic maintenance actions so that machine functions safely and for a long service life.
Mast Carrier of attachment and load.
OP Overload Protection. Overload system to warn in case the machine is overloaded.
Operating time Number of hours machine has been in operation, shown on hour meter in cab.
Option Extra equipment for machine.
Overload system A warning system, LLMC (Longitudinal Load Moment Control). The system is used for
stationary load handling, to not jeopardise the machine’s forward stability. LLMC is not de-
signed to control lateral stability or stability when operating.
Pilot oil pressure A low control pressure to, for example, a valve.
Planetary gear Type of transmission with gears in constant engagement (constant mesh).
Product alternative One of several alternatives is selected for a machine, e.g. engine alternative.
Proportional valve An electro-magnetically controlled valve. If a current is applied, the valve is activated in
proportion to the current’s amplitude. In simple terms, infinitely variable valve, as opposed
to on/off. For example, found on transmission’s valve housing.
Reachstacker Machine with special lift boom and top lift attachment for containers.
Refrigerant Fluid/gas in air conditioning. May only be handled by authorised trained personnel.
Rotation bar Rotating unit on attachment, rotates attachment in relation to lift boom.
Securing machine for transport Actions before transporting machine.
Serial number Unique machine designation. On machine plate.
Service position How machine should be safely positioned before service may be started.
Servo A small movement by the user results in a large angle, i.e. servo steering.
Servo pressure A low control pressure to control a higher pressure, for example, to a valve.
Side shift Parallel sideways movement of attachment.
Solenoid valve An electromagnetically controlled valve. See also proportional valve.
Spirit Delta Enclosed type of cab.
SPN Suspect Parameter Number.
Spreading (positioning) Widening of attachment.
Steering axle Wheel axle with steering.
Tilting Load is leaned forward or backward.
Torque converter Hydraulic, variable clutch.
Transmission oil Oil for transmission and torque converter. See specifications, operator’s manual.

10 Terminology 235
Term Description
Twistlocks Four locking pins, one in each corner of the attachment, pushed down in corresponding
holes in container and twisted to lock the container when lifting.
Type designation Indicates machine type and capacity. See also machine model.
UTTO-oil Universal Tractor Transmission Oil.
Valve slide Moveable part in valve. Determines oil’s path.
Variable displacement Adjustable volume (capacity) of a pump.
Variable pump Pump with adjustable flow rate.
Wet brakes Brake discs in oil bath.
Wheelbase Distance between drive axle and steering axle.
Working hydraulics All load handling functions, that is, lift and lower, tilt, side shift, spreading (extension) and
levelling.

236 10 Terminology

11 Index
About the documentation kit 6 Operating menu for engine and transmission 73
About the operator’s manual 3 Operating menu for heating /air conditioning system 77
Air filter, engine 180 Operating menu for service 77
ANSI/ITSDF marking 10 Operating menu for service interval 77
Battery and battery disconnector 192 Operating menu for system voltage 74
CE-marking 10 Operating menu for transmission and hydraulics 74
Checking accumulators 191 Operating menu statistics 75
Cleanliness 175 Operating menus 72
Control lever 59 Overview 23
Control system 72 Overview description 24
Cooling system 181 Parking brake 146
Daily inspection 170 Pedals 62
Daily inspection 87 Plates 29
Description DRF 400-450 23 Reading instructions 4
Driver’s seat 66 Running-in 86
Engine oil 183 Safety 7
Environment and standards 219 Safety and emergency equipment 8
Error code indication 90 Service 200
Error code information on display 90 Service brake 145
Error code tables 94 Service position 218
Error codes 88 Specifications 223
Event-controlled information 78 Starting engine 141
Fire 20 Steering 145
Foreword 3 Steering wheel 63
Fuel system 177 Stopping engine – parking 151
Functions for load handling 163 Switches 48
Fuses for electrical system 195 Terminology 233
Gear selector and Towing 204
multi-function lever 57 Transmission oil 183
Gearshifting 143 Transporting load 158
Handling 83 Transporting the machine 203
Heating / Air conditioning 148 Transporting the machine 207
Heating / Air conditioning 69 Tyres and rims 188
Hydraulic system 186 Unloading 161
Identification of the machine 23 Warming up 142
Ignition 47 Warning and indicator lights 42
Information menu for printer 76 While operating 139
Inspection and maintenance 169 Windscreen washer 179
Inspection and maintenance 6
Instruments 46
Instruments and controls 37
Keep in mind 11
Lifting and transporting the machine 206
Lifting load 154
Lifting machine 207
Lighting 199
Load handling 152
Long-term storage 218
Main fuses for electrical system 194
Maintenance 173
Mechanical release of parking brake 205
Oil, brake system 185
Operating 139
Operating menu for container counter 74
Operating menu for dynamic scale 73
Operating menu for dynamic scale 75
Operating menu for engine 73
Declaration of Conformity
We, Cargotec Sweden AB, SE-340 10 Lidhult, (Registration No. 556014-5418) herewith
declare that the machine,
Type Reachstacker
Model DRF450-65S5
Serial No A113.XXXXX
Year of construction 2010
Engine VOLVO TAD1250V
is manufactured in conformity with the requirements in

- The Machinery Directive 2006/42/EC;
- The Electro Magnetic Compatibility Directive 2004/108/EC
the harmonised standard EN 1459 Safety of industrial trucks

– Self propelled variable reach trucks.
Name
Position Head Of Counterbalanced Products
Place, Date of Issue Signature

2A_TEST_R_GB
Blnk.lxf
Cargotec improves the efficiency of cargo flows by offering solutions for
the loading and unloading of goods on land and at sea – wherever cargo Cargotec Sweden AB
is on the move. Cargotec’s main daughter brands for cargo handling Torggatan 3
SE-340 10, Lidhult, Sweden
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Operators Manual DRF400-450

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Operators Manual DRF400-450

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Reachstackers 40-45 tonnes

1.1 About the operator’s manual

Thank you for choosing Cargotec as your machine supplier. We hope

Operator’s manual, purpose

This Operator’s manual applies to machine DRF 400-450.

The operator’s manual should always be kept in the machine.

About machine version

The information in this operator’s manual corresponds to the ma-

This machine is manufactured by Cargotec Sweden AB,

Operator’s manual DRF 400-450 IDRF03.03GB

1.1.1 Reading instructions

This operator’s manual contains warnings that involve your safety.

Important information is denoted with NOTE and is intended to facili-

IDRF03.03GB Operator’s manual DRF 400-450

Read operator’s manual

Operator’s manual DRF 400-450 IDRF03.03GB

1.2 About the documentation kit

The following documentation is supplied with the machine:

The documentation is ordered from the dealer for Cargotec.

1.3 Inspection and maintenance

For satisfactory function of the machine to the lowest cost, mainte-

For other maintenance not included in this operator’s manual (service

IDRF03.03GB Operator’s manual DRF 400-450

Important to read the operator’s

Operator’s manual DRF 400-450 IDRF03.03GB

• The machine may not be operated on public roads unless it has

• The machine may only be operated by specially trained operators

Machine operation is prohibited:

2.1 Safety and emergency

A good working environment has safety and warning equipment to

4. Electrically powered loud air horn

IDRF03.03GB Operator’s manual DRF 400-450

8. Camera with monitor

12. Emergency exit, right door and rear window ( )

Operator’s manual DRF 400-450 IDRF03.03GB

(Declaration of Conformity, only applies to machines marketed

2.3 ANSI/ITSDF marking

Only applies to machines for the North American market.

For additional information, see standards under chapter 8 Environ-

IDRF03.03GB Operator’s manual DRF 400-450

2.4 Keep in mind

Turn off the electric power with the battery

Operator’s manual DRF 400-450 IDRF03.03GB

During work shifts

Extreme hazard to personal health and risk of proper-

Never walk under a suspended load. Never walk un-

Extreme hazard to personal health and risk of proper-

Make sure that no persons stand or walk under a

Extreme hazard to personal health and risk of proper-

Only use equipment that is approved by Cargotec.

Very sudden braking. Risk of machine tipping over,

Stop the machine before applying the parking brake.

IDRF03.03GB Operator’s manual DRF 400-450

Extreme hazard to personal health and risk of proper-

• Always check that no persons are in the way of the

• The operator must always face in the travel direc-

• The operator must adapt the speed to the load and

• The operator must pay extra attention and operate

• Always operate carefully so that the attachment

• Use available visibility-enhancing equipment

Operator’s manual DRF 400-450 IDRF03.03GB

Risk of roll-over and tipping! Risk of load damage to

Respect the lifting capacity of the machine and exer-

• The machine must only be operated on even sur-